Process for regenerating a monolithic, macro-structural, inter-penetrating elastomer network morphology from ground tire rubber particles

ABSTRACT

Crumb rubber obtained from recycled tires is subjected to an interlinked substitution process. The process utilizes a reactive component that interferes with sulfur bonds. The resulting treated rubber exhibits properties similar to those of the virgin composite rubber structure prior to being granulated, and is suitable for use in fabricating new tires, engineered rubber articles, and asphalt rubber for use in waterproofing and paving applications.

INCORPORATION BY REFERENCE TO RELATED APPLICATIONS

Any and all priority claims identified in the Application Data Sheet, orany correction thereto, are hereby incorporated by reference under 37CFR 1.57. This application is a continuation of U.S. application Ser.No. 16/803,335, filed Feb. 27, 2020, which is a divisional of U.S.application Ser. No. 16/497,775, filed Sep. 25, 2019, now U.S. Pat. No.10,662,320, which is the national stage in the United States of PCTInternational Application No. PCT/US2018/028656, filed Apr. 20, 2018,which claims the benefit of U.S. Provisional Application No. 62/489,878,filed Apr. 25, 2017, U.S. Provisional Application No. 62/541,610, filedAug. 4, 2017, U.S. Provisional Application No. 62/569,374, filed Oct. 6,2017, U.S. Provisional Application No. 62/613,744, filed Jan. 4, 2018,and U.S. Provisional Application No. 62/621,465, filed Jan. 24, 2018.Each of the aforementioned applications is incorporated by referenceherein in its entirety, and each is hereby expressly made a part of thisspecification.

FIELD OF THE INVENTION

Crumb rubber obtained from recycled tires is subjected to a processinvolving phase reticulation induced sulfidic metathesis. The processutilizes a reactive component that interferes with sulfur bonds. Theresulting rubber, subjected to interlinked substitution, exhibitsproperties similar to those of the virgin composite rubber structureprior to being granulated, or other polymeric materials, and is suitablefor use in fabricating new tires, engineered rubber articles, andasphalt rubber for use in waterproofing and paving applications.

BACKGROUND OF THE INVENTION

In 2015, end-use markets consumed 87.9% percent by weight of the scraptires generated in the U.S. The total volume of scrap tires consumed inend use markets in the U.S. reached approximately 3551 thousand tons oftires. RMA estimates that about 4038 thousand tons of tires weregenerated in the U.S. in 2015. Of those tires, 25.8% were used toproduce ground rubber, 48.6% for tire derived fuel, 11.4% were landdisposed, 7.0% were used in civil engineering, and 7.1% went tomiscellaneous uses (0.7% to electric arc furnace, 1.3% to reclamationprojects, 2.6% were exported, and 2.6% went to other uses). In 1990,only eleven percent of tires were consumed on a per tire basis. Positiveend-use market results in 2015 were primarily the result of high ratesof TDF use and lower exports. In the long term, the need to expand alleconomically viable and environmentally sound markets for scrap tires isstill an imperative. Scrap tires were consumed by a variety of scraptire markets, including tire-derived fuel, civil engineering and groundrubber applications. Other smaller markets and legal landfillingconsumed the remaining annually-generated tires.

Key scrap tire markets include tire derived fuel, ground rubber, civilengineering and other markets. In tire derived fuel applications, scraptires are used as a cleaner and more economical alternative to coal asfuel in cement kilns, pulp and paper mills and industrial and utilityboilers. Ground rubber applications utilize approximately 1020 thousandtons of scrap tires, or over 25 percent of the volume of scrap tiresgenerated each year. Ground rubber is produced by grinding scrap tiresinto size defined pieces. Ground rubber applications include new rubberproducts, playground and other sports surfacing and rubber-modifiedasphalt. Ground rubber also includes larger pieces of rubber used aslandscaping mulch, and loose fill playground material. The playgroundand mulch market was the most dynamic segment in the ground rubbermarket during this period. The asphalt market uses ground rubber tomodify the asphalt binder used in road paving, resulting in quieter,more durable roads. The civil engineering market consumes approximately274 thousand tons of tires per year, about 7.7 percent of the totaltires to market, and consists of tire shreds used in road and landfillconstruction, septic tank leach fields, alternative daily cover andother construction applications. Additional smaller markets for scraptires exist that consume approximately 7% of annually generated scraptires. These markets include tires consumed in electric arc furnaces(steel manufacturing), professionally engineered tire bales and productspunched, pressed or stamped from scrap tires. Total tire rubber consumedin ground rubber markets is about 1.36 billion pounds. The total scraptires diverted to these ground rubber markets is about 1.02 million tons(62 million tires). The percent of total pounds of ground rubberconsumed in the market in 2015 is as follows: sport surfaces 25%,playground mulch 22%, molded/extruded products 35%, asphalt 15%,automotive uses 2%, and export 1%.

Stockpiles of scrap tires historically began to be created around the1960s and 1970s when tires were diverted from landfills, but recyclingmarkets for them were not functional. Stockpiles proved to be prone tocatastrophic fires which created air and water pollution.

Worldwide rubber tire production is responsible for generatingapproximately 99% of worldwide, end-of-life (EOL) tire scrap. About 1.1billion scrap tires are generated annually, corresponding to roughly 12million tons of scrap tire. Due to the punishing physical propertiesrequired of a new tire, tires embody a carefully engineered weavingtogether of steel and fiber cords with a mineral and carbon-filledrubber blend, all cross linked to a highly tenacious structure. The EOLtire is challenging to breakdown to its original essential elements. Thepotentially highest value component—the rubber—is particularly difficultto reclaim, due to the vulcanization process it is subjected to. As aresult EOL tires that are no longer suitable for use on vehicles due towear or irreparable damage are typically either subject to pyrolysis(e.g., to generate energy for use in cement manufacturing), or ground upto be used as filler (e.g., in asphalt pavement, new tires, constructionor landscaping materials).

SUMMARY OF THE INVENTION

While extensive research efforts have been devoted to development ofmethods for devulcanizing vulcanized rubber, e.g., tire rubber, a methodfor recovery or transformation of tire rubber into a commercially viableproduct having properties similar to virgin composite rubber hasheretofore not been developed.

An interlinked substitution method for extracting, utilizing, ortransforming the natural or synthetic rubber in waste tires and othervulcanized rubber scrap offers potential as a low cost source forquality natural or synthetic rubber. Such reclaimed materials mayexhibit properties similar to, or even superior to, those of the productfrom which they are derived. Rubber subjected to processes as describedherein is variously referred to herein as “treated rubber”, “activatedrubber”, “interlinked substituted rubber”, “PTR rubber”, “post reactorground tire rubber”, “EOL tire rubber crumb-derived rubber” or the like.

One of the objects of the methods described herein is to processvulcanized rubber products or other cross linked rubber containingproducts, e.g., as found in end-of-life (EOL) rubber tires, into a formsuitable for use as a raw material in the fabrication of articles ofmanufacture that would conventionally be fabricated from virgin rubbersubjected to vulcanization, e.g., new tires or other vulcanized rubberproducts. The vulcanized rubber subjected to the methods describedherein is typically provided as a conventionally available, 30 mesh,end-of-life, ground tire rubber particle (GTRP). It is subjected to amethod whereby it is transformed into a crosslink re-aligned, 5-10micron moiety, wherein the micro-moiety may be re-fabricated into amonolithic, macro-structure characterized by an interpenetratingelastomer network exhibiting physical properties substantially analogousto the macro-structural properties of the original, EOL tire rubberprior to being size-reduced to the 30 mesh particle.

Two inter-dependent, parallel and nearly simultaneous, interacting,process systems are successfully executed to achieve one or more of thevarious objectives of the methods described herein. To ensure a desiredend result, process management can optionally be data driven, in realtime and/or by post-process analysis of the integration of the micronmoiety into finished product, macro-structure(s).

In the first system, an aqueous, chemical solution is provided intowhich the particle is immersed. The aqueous, chemical solution acts todissociate the transverse sulfuric bridge from a pendant elastomer bondin a manner that pre-nucleates the pendent site for a subsequent,re-alignment and crosslink. This dissociation substantially preservesthe sulfidic bridge as an intact and bound ‘tether’ upon the companion,parallel non-pendant backbone to which it was originally fixed (e.g.,vulcanized).

In the second system, an electromagnetic-mechanical system is employedwhich stress-distorts the particle to a sub-hysteresis, strainthreshold. This maximizes the exposure of the elastomer crosslink sitesto the aqueous, chemical solution such that the chemical of the aqueous,chemical solution can operate at pico-second speed to perform thedissociative substitution described in the first system.

The fully vulcanized GTRP exhibits substantial resilience to distortionalong all three axes. This resilience is observed whether the externalforce is a compressive mechanical force, a tensile mechanical force, atorsional mechanical force, or a force that is electromagnetic innature. This resilience is manifest in a rapid recovery to thedimensional and dielectric ground state(s) of the rubber. The resiliencestrain is the interactive product of the two, interdependent processsystems described above being quicker than the distortion-relaxationcycle, inclusive of being properly coordinated.

The Joint Research Council (JRC) for the EC recently published aCritical Raw Material (CRM) study in December 2017 listing 27 materialssubject to supply disruption; a disruption that would result insignificant loss of economic sustainability. Natural rubber (NR) waslisted as one of the 27 materials. The process disclosed herein canprovide up to 70% of the natural rubber gap referred to in the CRMstudy.

In a first aspect, a method is provided for preparing a modified rubber,comprising: introducing an aqueous slurry comprising vulcanized rubberparticles and an organometallic compound into an electromechanicalreactor configured to generate a phase space environment withcavitation, so as to induce delamination of a rubber matrix within thevulcanized rubber particles as coordinated with disrupting sulfidiclinkages.

In an embodiment of the first aspect, the method further comprisesreestablishing sulfidic linkages to establish within the matrix sulfurbridge cross linked, re-aligned, laminates.

In an embodiment of the first aspect, delamination is associated with aportion of rigid sulfidic bridges of the vulcanized rubber particlesbecoming unbound at an original methyl carbocation while remainingtethered at an original allylic carbocation.

In an embodiment of the first aspect, the organometallic compoundcomprises a metal having octahedral molecular geometry.

In an embodiment of the first aspect, the organometallic compoundcomprises a metal ion selected from the group consisting of Co²⁺, Cu²⁺,Ni²⁺, Zn²⁺, and Mn²⁺.

In an embodiment of the first aspect, the organometallic compoundcomprises an organic anion as a ligand to the metal ion.

In an embodiment of the first aspect, the organic anion comprisesacetate ion.

In an embodiment of the first aspect, the organometallic compound iscopper acetate.

In an embodiment of the first aspect, the organometallic compound is ametal salt that undergoes a phase change from solid to liquid or vaporin a range of 100-150° C.

In an embodiment of the first aspect, a temperature in theelectromechanical reactor is maintained at ambient by use of a coolingjacket or cooling coils.

In an embodiment of the first aspect, the vulcanized rubber crumbs havea particle size greater than 200 mesh.

In a second aspect, an electromechanical reactor is provided comprising:a rotor having a plurality of slots; and a stator, wherein theelectromechanical reactor is configured to create a phase spaceenvironment by generating a mixture of entrained air, an organometalliccompound, and ground tire rubber particles in a liquid subject tocavitation.

In a third aspect, a rubber-based heterogeneous matrix is providedcomprising an interpenetrating network of two or more elastomers, thenetwork comprising sulfur bridge cross linked, re-aligned, intermingledlaminates having an average spacing of from 10 nm to 5 microns, whereineach laminate comprises one of the two or more elastomers.

In an embodiment of the third aspect, carbon black particles aredispersed amongst the laminates.

In an embodiment of the third aspect, the two or more elastomerscomprise virgin natural rubber and an elastomer derived from ground tirerubber.

In an embodiment of the third aspect, the two or more elastomerscomprise virgin styrene butadiene/butadiene rubber and an elastomerderived from ground tire rubber.

In an embodiment of the third aspect, two of the two or more elastomershave different backbone chemistries.

In an embodiment of the third aspect, the two of the two or moreelastomers having the different backbone chemistries are woven togetherand then cross linked separate from one another.

In a fourth aspect, a sheet of the rubber-based heterogeneous matrix ofthe third aspect or any of its embodiments is provided.

In an embodiment of the fourth aspect, the sheet exhibits an anisotropyin length tensile strength to width tensile strength, wherein theanisotropy in length tensile strength to width tensile strength is from1.1:1 to 3:1.

In a fifth aspect, a laminate comprising a plurality of the sheets ofthe fourth embodiment is provided.

In an embodiment of the fifth aspect, each of the sheets has a thicknessin a range of 10 to 70 microns.

In an embodiment of the fifth aspect, each of the sheets is vacuum-heatfused and cross linked to an adjacent sheet.

In an embodiment of the fifth aspect, each of the sheets is oriented 30to 45 degrees to an anisotropic grain of an adjacent sheet.

In a sixth aspect, a ground tire rubber composite structure is providedhaving an unbound, reptated internal morphology, wherein a portion ofthe rigid sulfidic linkages therein are each tethered at an originalallylic carbocation and unbound at an original methyl carbocation.

In a seventh aspect, a vulcanized rubber is provided, wherein a portionof the rigid sulfidic linkages therein are each tethered at an originalallylic carbocation and unbound at an original methyl carbocation, andwherein a portion of polymer backbones within the vulcanized rubber aresubstituted by an acetate moiety.

In an eighth aspect, a rubber tire is provided, wherein from 3% byweight to 15% by weight of the rubber in the tire is prepared by amethod substantially as described herein.

In a ninth aspect, a rubber tire is provided, wherein from 15% by weightto 100% by weight of the rubber in the tire is prepared by a methodsubstantially as described herein.

In a tenth aspect, a tire tread is provided, comprising from 10% byweight to 50% by weight of an interlinked substituted rubbersubstantially as described herein.

In an eleventh aspect, a tire sidewall is provided, comprising from 10%by weight to 100% by weight of an interlinked substituted rubbersubstantially as described herein.

In a twelfth aspect, an asphalt-rubber binder is provided, comprisingfrom 5% by weight to 95% by weight of an interlinked substituted rubbersubstantially as described herein.

In a thirteenth aspect, an asphalt emulsion is provided, comprising from5% by weight to 95% by weight of an interlinked substituted rubbersubstantially as described herein.

In a fourteenth aspect, an asphalt roofing material is provided,comprising from 5% by weight to 95% by weight of an interlinkedsubstituted rubber substantially as described herein.

In a fifteenth aspect, an interlinked substituted rubber substantiallyas described herein is provided.

In a sixteenth aspect, a tire tread, tire sidewall, roofing membrane,high dielectric electrical tape, tank lining, reservoir lining, trenchlining, bridge underlayment, wire harness wrap, self-bonding wireharness wrap, shoe soles, rubber boots, electrical tape, foundationwaterproofing, parking garage waterproofing, hose, belt, or moldingcomprising an interlinked substituted rubber product as described hereinis provided.

Any of the features of an embodiment of the first through sixteenthaspects is applicable to all aspects and embodiments identified herein.Moreover, any of the features of an embodiment of the first throughsixteenth aspects is independently combinable, partly or wholly withother embodiments described herein in any way, e.g., one, two, or threeor more embodiments may be combinable in whole or in part. Further, anyof the features of an embodiment of the first through sixteenth aspectsmay be made optional to other aspects or embodiments. Any aspect orembodiment of a method can be performed by a system or apparatus ofanother aspect or embodiment, and any aspect or embodiment of a systemor apparatus can be configured to perform a method of another aspect orembodiment.

DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an electromechanical reactor environment (EMRE) includingrotor 101, stator 102, and slots/cavitation portals 103 cooperating togenerate a ground tire rubber particle (GTRP) slurry flow pattern 104.

FIG. 2 depicts a process for preparing a GTRP slurry for the EMRE ofFIG. 1, utilizing a submerged EMRE head 202 in a mix tank 201.

FIG. 3A depicts the process of the GTRP traversing a “phase spacetunnel” wherein differential-cyclical, mechanical stress and stericfield polarization are applied.

FIG. 3B illustrates the phase space tunnel 303 between the EMRE rotor301 and the compression gate 302.

FIG. 3C illustrates the effect of rapidcompression-stretching-decompression of the GTRP.

FIG. 4A depicts the process of cavitation as generated by the EMRE rotor401 and the compression gate 203 as entrained air 406, GTRP 405, andaqueous organometallic matrix 407 pass through the compression gate.

FIG. 4B includes process control variables for control of conditions inthe phase space tunnel region.

FIG. 4C provides a table listing GTRP slurry control variables.

FIG. 4D provides a table listing EMRE process control variables.

FIG. 5A schematically depicts the chemotactic sulfidic bridge tethereffect.

FIG. 5B provides an illustration of carbocation stability.

FIG. 6A depicts a summary of GTRP slurry formation.

FIG. 6B depicts the process of an organometallic compound developingligands in the process of an embodiment.

FIG. 7A depicts the morphology of ground state vulcanized GTRP,EMRE-conditioned GTRP, and a regenerated interpenetrating elastomernetwork of treated rubber.

FIG. 7B provides a flowchart of fabricating a monolithic rubber macrostructure including a regenerated interpenetrating elastomer network.

FIG. 8A depicts a Parallel, Continuous-flow, Micro-synthesis Reactor(PCMR).

FIG. 8B depicts a space saving tube configuration for use, e.g., in aPCMR.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following description and examples illustrate an embodiment of thepresent invention in detail. Those of skill in the art will recognizethat there are numerous variations and modifications of this inventionthat are encompassed by its scope. Accordingly, the description of anembodiment should not be deemed to limit the scope of the presentinvention.

INTRODUCTION

An ambient, end of life (EOL), ground tire rubber (GTR) particle in thesize range of approx. 600 microns (30 mesh), has a cross sectioncomposed of either the old tire tread or the tire side wall or acombination of the two. It may be generally characterized as aheterogeneous matrix of an interpenetrating, cross linked, elastomernetwork filled with inorganic substances, primarily carbon. Dependingupon whether it is primarily tire tread or sidewall in origin theprimary entangled elastomers will be natural rubber (NR) or styrenebutadiene/butadiene rubber (BR S-BR), with the BR and S-BR typicallyhaving the larger mass component in the tread for better wear and thesidewall having an NR bias for improved flexural qualities. Thecrosslink may generally be described as elemental sulfur and/or acomplex compound incorporating sulfur as its principal element, e.g., apolysulfidic chemical.

During tire construction the interpenetrating elastomer networks areformed using a sequential crosslink of the predominant elastomer (NR orS-BR) followed by the crosslink of the secondary elastomer, such thatthe secondary elastomer is “bent” to conform to the already vulcanized,higher strength primary elastomer. This technique imparts mechanicalcharacteristics that are retained in the individual GTR particle.

A single vehicle tire, after being stripped of steel and fiberreinforcement will yield approximately sixteen pounds (16 lbs) ofreusable GTR, with truck tires yielding more. Over one billion EOL tiresare generated worldwide annually. About 50% are consumed as low valuefuel. Where possible, maximizing the reuse of this raw material for itsproven mechanical properties represents a substantial challenge, but, tothe extent achieved, a resource recovery value of as much as 200:1 isobserved when comparing its possible re-use in new tire construction tobeing consumed in a furnace for its BTU content.

Notably, recent detailed studies of the environmental advantages such areversal of EOL-GTR usage, maximized, predicts that atmospheric carboncontribution might be reduced by the equivalent of shutting down 14 coalfired power plants (300,000 rail cars of coal) or removing six millionvehicles from the roads or planting an additional 62 million acres offorests (equivalent to an area the size of the state of Arizona) forcarbon sequestration. Accordingly, one object of the methods andcompositions discussed herein is to prepare the GTR particle so that itmay be recombined with similar particles or materials into a monolithicunit which may be integrated into the full spectrum of industrial rubbergoods manufactured worldwide.

A method is provided that allows one to achieve the objective ofpreparing, augmenting, and then recombining the GTR particle(s) in sucha manner that the individual, complex, heterogeneous, cross linkedmoieties are built into a re-entangled, monolithic structure,substantially composed of the original GTR; with uniform mechanicalproperties which are at least equivalent to the whole tire properties ofthe rubber matrix prior to the granulation process. Achievement of thisobjective is demonstrated by the end product being competitivelyre-introduced as feedstock for new tire and industrial rubberproduction.

The macro-characteristics of a ground tire rubber particle may be viewedfrom the perspective that it is a bit like an egg that has beenscrambled, and therefore it cannot ever be un-scrambled. Similarly, itcan be viewed as like an old car that has been crushed at a recyclingyard, such that it can never be un-bent to its original specification.To some degree both these metaphors have merit. However, upon a closerexamination a list of unusual mechanical qualities and conditionsbecomes apparent, which, if exploited, provide an opportunity to recoverthis complex resource in a commercially and technically viable way;whereby complete resource recovery emerges.

In GTR, the qualities and conditions of opportunity include thefollowing. A substantial inventory exists of un-bound, eight sidedsulfur rings. Previous accelerator chemistry byproducts have beendegraded such that they may be mitigated so as not to interfere withfurther crosslinking processes. Existing crosslink density and sulfurbond length can be accurately assessed by chemical probe. A substantial,recoverable, ineffective elasticity exists within the interpenetratingdensity due to loop crosslinks within a single molecular backbone. Theoriginal, new tire morphology has undergone rigorous physical challengescausing the remaining structure to be annealed. A very high particlesurface shoreline is presented as a result of the ambient grindingprocess. Substantial un-used allylic hydrogen and carbon sites remain inthe entangled polymer structure(s). Classic, transverse sulfur bridgeformation is well verified, providing a focused mechanistic model toapproach resource recovery.

The strategic effort, using these qualities and conditions, is to 1)gently unpack the dense GTR composite structure, 2) dislocate the leaststable attachment point of the transverse crosslink without negativelyaltering the elastomer molecule or the sulfur bridge, 3) install acomplimentary virgin polymer receptor upon a dislocation site, then 4)following subparticle mechanically induced leafing, re-crosslink theoriginal hinged, sulfur bridge at susceptible, dislocation sites alongthe elastomer backbone.

Unassisted, elemental sulfur will slowly crosslink functional rubberpolymers, but the process is too slow and has too many end propertydifficulties to be a commercially realistic alternative to acommercially successful vulcanization. Vulcanization as discussed hereinregards an accelerated sulfur vulcanization process as is practiced incommercial vulcanization.

Sulfur vulcanization was discovered by Charles Goodyear in 1839. After178 years of development, it is universally agreed that the processesare complex which result in the formation of the transverse sulfuricbridge between adjacent, interpenetrating rubber polymers. These bridgesin turn yield mechanical properties in an elastomeric material which arecritical to civilization. However, much progress has been made and many,definitive elements of the progression are well established.

While a free-radical mechanism had long been assumed to be thecontrolling phenomena, more recently, with the advent of more advancedmethods of discreet process characterization, a convincing presence hasnot been detected of the primary, theoretical radicals necessary tovalidate that mechanism. In contrast, an ionic mechanism has beenpredicted and validated using similar advanced process characterizationmethods. Since the modern vulcanization process involves many chemicalcomponents being mixed together at the start of the process, each(combination) with its own chemical reaction pathway, it is likely thatboth radical and ionic mechanisms are active but analysis reveals thatthe ionic mechanism is predominant.

A typical example (by wt. %) of an NR-BR tire compound is: NR 80%, BR20%, ZnO 5%, steric acid 2%, silica-talc 3%, carbon black 55%, aromaticoil 10%, elemental sulfur 1.7%, N-Cyclohexyl-2-benzothiazole sulfenamide(CBS—an accelerator) 1.2%, 2-(4-Morpholinothio)-benzothiazole (MBS—anaccelerator) 1.1%, and N-tert-butyl-2-benzothiazole sulfenamide (TBBS—anaccelerator) 1.1%.

The process begins in a heated mold, after the tire recipe componentshave been thoroughly distributed and dispersed. The vulcanizationprocess may be seen in three sequential events: 1) formation of theaccelerator complex chemistry, 2) formation of the crosslink precursor,and 3) completion of the crosslink.

Formation of the Accelerator

Using, by way of example, the popular 2-mercaptobenzothiazole (MBT)accelerator model, a consensus exists that a sulfonamide accelerator inthe presence of sulfur decomposes under heating into MBT and arespective amine. Progressively the MBT then reacts with the remainingsulfenamide molecules to auto catalytically form2,2′-dithiobenzothiazole (MBTS) thereby releasing the amine molecules.MBTS then reacts with elemental sulfur forming polysulfide an activesulfurating agent (persulfonium ion source). A possible reactionmechanism for precursor formation follows.

Formation of the Crosslink Precursor

This second stage reaction, feeding off of the newly formed acceleratorintermediate, which is bound to both ends of the forming sulfur chain,begins when the sulfurating agent reacts with a pendant structureattached to an isoprene or butadiene elastomeric molecule chain yieldingthe formation of a persulfonium ion (I). The resultant persulfonium ionthen reacts with a second isoprene or butadiene molecule by allylichydrogen scavenging to produce a polymeric methyl carbocation. Theformed intermediate, also referred to as a polythio-mercapbenzothiazylgroup introduces monomeric sulfur into a bonding position in the pendantgroup which is converted by a new carbocation into a double bond byanionic addition. This formation of the final double bond ultimatelyoccurs with sulfenamide decomposition to uncharacterized isomers nearthe reaction site.

Formation of the Crosslink

In the final step the backbone of the adjacent rubber polymer chain isattacked at an allylic carbon position which is susceptible tocarbocation by the polysulfide group bound onto the remaining ‘end’ ofthe elemental sulfur chain. The sulfur chain, in a final cross linkedform, may be up to twenty (20) atoms in length but typically does notexceed (7) atoms. The sulfur bridge may contain individual atoms butusually contains one or several elemental, eight sided sulfur rings(S₈). Longer chains may shorten when the cure time and temperature areextended beyond the completion of the crosslink; or during theassociated annealing process. It is important to note that no sulfidicchain can form until the otherwise dissociated, sulfur compound ‘maw’becomes attached at the precursor site. Only the last step of thecrosslink formation is detected in a moving die rheometry (MDR) curve.

Characterizing the Final Crosslink

Crosslink density and type are determined by chemical swelling methodand chemical probes, respectively; or by spectroscopy.

Elastically effective network chain crosslink density may be calculatedby the Flory-Rehner Equation once data is empirically ascertained.Subsequently, the same localized sample used to determine crosslinkdensity is subjected to a piperidine-propane-2-thiol chemical probe(PPTCP) which will determine the sulfidic crosslink (S>3) proportion.Further treated the same PPTCP sample may reveal the di-sulfidic andmono-sulfidic proportions using a piperidine-hexane-1-thiol chemicalprobe. Thereupon by percentage of the original crosslink density thepercentages of each may be computed and beneficially compared to the MDRcurve.

C MAS NMR spectra is cross validated by chemical probe method(s) withpolysulfide and mono sulfide resonance peaks at 57.5 and 50.4 ppmrespectively (B2 type structures by way of example); and resonant peaksof 37.3, 44.7, 48.2, 49.6, 50.6, 52.5, 54.8 and 57.5 ppm using one-halfthe sum of these areas to yield cross link density.

Estimation of Looping Probabilities

When a crosslink occurs between neighboring polymer chains it provideselasticity and shear modulus to the rubber composite. However wheneverthe crosslink forms within the same polymer chain it forms a loop and itis elastically ineffective and may be characterized as a flaw or weakspot in the structure of the vulcanized rubber matrix. Detailed analysisof the looping probability reveals that the occurrence of this unwantedcondition occurs within a range of 5-15% of the total number ofcrosslinks in a given commercially vulcanized rubber. Dependent upon thelocation of the unwanted crosslink the looped polymer molecular chaincan relegate from 5% to 20% of the rubber polymer to an ineffectivecyclic hydrocarbon. It is noted that the repeated elastomer morphologyof a GTRP processed by the methods of the embodiments has reducedsusceptibility to this phenomena.

Conventional Usage of Scrap Rubber in Tire

Excluding the rubber trimmings generated prior to the final heating andcross linking of new tires, it is estimated that less than 0.0004% byweight of all EOL tires are reincorporated into a new tire master batch.Such reincorporation has been successfully accomplished at master batchloadings of up to 3% by weight utilizing very fine, cryogenicallyprocessed ground rubber obtained from EOL tires. A loading of EOLtire-derived processed ground rubber greater than this has thus far notbeen feasible, in that the physical properties required of new tireapplications are not met at higher loading levels. Tire productiontypically begins with a base formula of components, with the baseformula developed by selection of raw material(s). This is then reducedto a master batch in high shear mixing equipment. Typically, the masterbatch is done in two phases: the master pass and the finish pass. Themaster pass combines various rubber species which are introduced assmall bales or sheets and are blended with fine powders of carbon blackand minerals, as well as a small quantity of process oil(s). This stepis performed at the high temperature required to lower the viscosity ofthe rubber elements such that the flow-resistant powder elements can beuniformly distributed in sufficiently small clusters or packets. Theseclusters or packets can then be subsequently dispersed to a minimalparticle size. The finish pass is done at a lower temperature andusually under process conditions that create more of a smearing actionof the heterogeneous elements. In the finish pass, rubber polymers arenot further degraded by high temperatures as in the master pass, and theuniformly distributed agglomerates of powder components are worked intosuch small physical size that they become dispersed within the freemolecular space of the rubber elements. Once the finish pass iscompleted, the master batch bales are ejected from the mixer and rolledinto thin sheets (referred to as milling). The milled sheets are used tolay up, on specialized forming equipment, the tire carcass prior tobeing placed in a compression molding press for final crosslinking bythermal and/or chemical means.

Crosslinking accelerants include mercapto group or sulfur-based (e.g.,elemental sulfur and/or, accelerator derivatives ofN-tert-butyl-2-benzothizolesulfenamide (TBBS)). The sulfur-basedcrosslinking agents which react with sites in the master batch at orabove a prescribed temperature may be partially introduced at both themaster pass and the finish pass phase. The crosslinking during the finalheating of the tire carcass causes the reactive sites in the variousrubber elements to build a sufficient crosslink density to achieve thefinal physical properties required to meet the sustained load and heatenvironment to which the tire will be subjected.

A method for targeting the crosslink precursor site has been developedwhich enables interlinked substitution of EOL tire, such that afunctionally re-aligned, re-cross linkable, submicron particle rubbercan be obtained. This rubber is suitable for reintroduction into newtire production at levels of up to 100% by weight of subsequent new tiremaster batch production. The new tires, utilizing such EOL tire-modifiedfeedstock, exhibit performance qualities equivalent or similar to thoseachieved when all virgin materials are utilized.

Rubber from End-of-Life Tire Scrap

Rubber-containing crumb is manufactured from two primary feedstocks:tire buffings, a byproduct of tire retreading, whole tire, and scraptire rubber. Scrap tire rubber comes from three types of tires:passenger car tires; truck tires; and off-the-road tires. End productyields for each of these tire types are affected by the tire'sconstruction, strength and weight. On average, 10 to 16 pounds ofend-of-life tire crumb can be derived from one passenger tire. Othersources of rubber-containing crumb includes products containing or madeusing recycled rubber-containing crumb, e.g., new rubber products,playground surfacing, rubber mulch, drainage aggregate, constructionfill material, scraps from manufacturing, and the like.

Tires are composite structures containing a number of components. Thetire carcass is composed of the tread, bead, sidewall, shoulder, andply. Tires are formed from components such as natural and/or syntheticrubber, cords, and filler. The polymer most commonly employed for thetread and encasement of the cords is a blend of NR and S-BR copolymer.Cords form the ply and bead of the tire, and provide tensile strengthnecessary to contain the inflation pressure. Cords can comprise steel,natural fibers such as cotton or silk, and synthetic fibers such asnylon or Kevlar. Fillers can include silica and carbon black. Arepresentative tire can comprise one or more of: synthetic rubber,natural rubber, sulfur and sulfur-containing compounds, silica, phenolicresin, oil (aromatic, naphthenic, and/or paraffinic), fabric (polyester,nylon, etc.), petroleum waxes, pigments (zinc oxide, titanium dioxide,etc.), carbon black, fatty acids, miscellaneous inert materials, andsteel wire.

The typical passenger tire comprises 14% natural rubber, 27% syntheticrubber, 28% carbon black, 14-15% steel, and 16-17% fabric, fillers,accelerators, antiozonants, and other miscellaneous components. Theaverage weight of a new passenger car tire is 25 lbs., and for a scrappassenger tire 22 lbs. Truck tires typically contain 27% natural rubber,14% synthetic rubber, 28% carbon black, 14-15% steel, and 16-17% fabric,fillers, accelerators, antiozonants, and other miscellaneous components.The average weight of a new truck tire is 120 lbs., and for a scraptruck tire 110 lbs. Other types of tires can contain higher amounts ofsynthetic and/or natural rubber, e.g., 70% (by weight) rubber, 15%steel, 3% fiber, and 12% of other materials such as inert fillers.Rubber is found in tire components including tread, innerliner, beads,belts, and the like. The percent rubber by weight in a new passengertire is typically as follows: 32.6% in tread; 1.7% in base, 21.9% insidewall, 5.0% in bead apex, 1.2% in bead insulation, 11.8% in fabricinsulation; 9.5% in insulation of steel cord, 12.4% in innerliner, and3.9% in undercushion.

The rubber compounds employed in a typical tire, along with associatedmaterials, are set forth in Table 1. The methods described herein aresuitable for processing tire tread, base, sidewall, as well asinnerliner, and are also suitable for processing other materialscontaining vulcanized (or otherwise cross linked) natural rubber,styrene-butadiene rubber, and isobutylene-isoprene rubber. As furtherdescribed herein, the other components, e.g., carbon black, present inEOL tire or other vulcanized-rubber containing articles of manufacturemay in some embodiments remain in the rubber subjected to the processesdescribed herein, with no processing conducted to impact the propertiesor amounts of the other component(s). In other embodiments, the rubbermay be subjected to further processes to enrich or minimize theseadditional components, or change their properties.

TABLE 1 Tread Base Sidewall Innerliner (PHR) (PHR) (PHR) (PHR) NaturalRubber 50.0 100.0 75.0 Styrene-Butadiene Rubber 50.0 25.0Isobutylene-Isoprene Rubber 100.0 Carbon Black (Grade N110) 50.0 15.020.0 Carbon Black (Grade N330) 25.0 35.0 Carbon Black (Grade N765) 50.0Processing Oil 7.5 5.0 5.0 3.0 Antioxidant 1.0 0.75 1.0 1.0 AntioxidantWax 2.0 Stearic Acid 2.0 4.0 3.0 1.5 Zinc Oxidant 5.0 5.0 5.0 5.0Accelerator (High) 1.0 0.7 Accelerator (Middle) 1.25 0.4 Accelerator(Low) 0.4 Sulfur 2.5 3.0 2.8 2.0 *PHR = Per Hundred Rubber, parts on aweight basis *Carbon grade = ASTM grading: Particle size and structureof carbon are different.

There are approximately 2.5 pounds of steel belts and bead wire in apassenger car tire. This material is made from high carbon steel with anominal tensile strength of 2750 MN/m². The steel tire cord compositionof a typical tire is set forth in Table 2.

TABLE 2 Steel Belts Bead Wire Carbon 0.67-0.73% 0.60% min. Manganese0.40-0.70% 0.40-0.70% Silicon 0.15-0.03% 0.15-0.30% Phosphorus 0.03%max. 0.04% max. Sulfur 0.03% max. 0.04% max. Copper Trace Trace ChromiumTrace Trace Nickel Trace Trace Coating 66% Copper 98% Brass 34% Zinc 2%Tin

Whole tires can be ground to yield rubber particles mixed with othercomponents of the tire. Methods for producing rubber containingparticles from tires are known in the art. The used tires (or shreds orgranules thereof) can be subjected to an optional cleaning step (e.g., awater wash). Tires can be recycled by subjecting them to an initialshredding step, then subjecting the shreds to a granulation process toyield an initial granulate having dimensions of 1-3 cm. Grinding can beconducted under ambient conditions (e.g., in a granulator or a crackermill) or cryogenic conditions.

Ambient grinding is a multi-step processing technology that uses aseries of machines (usually three) to separate the rubber, metal, andfabric components of the tire. Whether using granulation equipment orcracker mills, the first processing step typically reduces the originalfeedstock to small chips. The second machine in the series will grindthe chips to separate the rubber from the metal and fabric. Then afinishing mill will grind the material to the required productspecification. After each processing step, the material is classified bysifting screens that return oversize pieces to the granulator or millfor further processing. Magnets are used throughout the processingstages to remove wire and other metal contaminants.

In the final stage, fabric is removed by air separators. Rubberparticles produced in the granulation process generally have a cutsurface shape and rough texture, with similar dimensions on the cutedges.

Cracker mills use two large rotating rollers with serrations cut in oneor both of them. The roll configurations are what make them different.These rollers operate face-to-face in close tolerance at differentspeeds. Product size is controlled by the clearance between the rollers.Cracker mills are low speed machines operating at about 30-50 RPM. Therubber usually passes through two to three mills to achieve variousparticle size reductions and further liberate the steel and fibercomponents. These mills do not have screens built into the mill and assuch the mill itself does not control the final particle. A stand-alonescreening system will separate “sized” particles from oversize granulesfollowing the mill and re-circulate the oversize products. The particlesproduced by the cracker mill are typically long and narrow in shape andhave a high surface area.

Cryogenic processing uses liquid nitrogen or other materials/methods tofreeze tire chips or rubber particles prior to size reduction. Mostrubber becomes embrittled or “glass-like” at temperatures below −80° C.The use of cryogenic temperatures can be applied at any stage of sizereduction of scrap tires. Typically, the size of the feed material is anominal 2 inch chip or smaller. The material can be cooled in a tunnelstyle chamber, immersed in a “bath” of liquid nitrogen, or sprayed withliquid nitrogen to reduce the temperature of the rubber or tire chip.The cooled rubber is size-reduced in an impact type reduction unit,centrifuge, or hammer mill. This process reduces the rubber to particlesranging from ¼ inch minus to 30 mesh, with the majority of the particledistribution between ¼ inch minus and 20 mesh. A typical throughput is4,000 to 6,000 pounds per hour. Cryogenic grinding avoids heatdegradation of the rubber and produces a high yield of product that isfree of almost all fiber or steel, which is liberated during theprocess.

Wet grinding, is a processing technology used to manufacture particlesthat are 40 mesh and finer. The wet grind process mixes partiallyrefined crumb rubber particles with water creating a slurry. This slurryis then conveyed through size reduction and classification equipment.When the desired size is achieved, the slurry is conveyed to equipmentfor removing the majority of the water and then drying. Aside from theuse of water, the same basic principles that are used in an ambientprocess are utilized in a wet grinding process. The major advantage fora wet grind process is the ability to create fine mesh crumb rubber.While products as coarse as 40 mesh are produced, the majority of theparticles are 60 mesh and finer. A percentage of the overall throughputis finer than 200 mesh. Another advantage for a wet grind process is thecleanliness and consistency of the crumb rubber produced. The processwashes the crumb rubber particles. The wet process removes the fineparticles of fiber from the crumb rubber making a very clean product.

The initial granulate contains steel, rubber, and textile components.The steel is typically recovered using a multistage magnetic separationprocess to minimize the loss of rubber. This can entail a first steputilizing a high strength twin pole overband cross belt separator magnetto remove metal containing particles in a first step. The second stepinvolves a magnetic drum separator or magnetic pulley utilizing highstrength rare earth magnets. The axial magnetic field causes the metalcontaining particles to tumble and release entrapped rubber. For finerubber material that is fed into a powder grinder, a plate magnetsuspended close to the product over the conveyor can lift and removefine wire fragments. Testing can be conducted to determine metalcontent, e.g., by using a magnetometer.

The fiber can be recovered using modified gin machinery as known in thetextile industry. A two step process is typically employed, where cleanfiber is removed from EOL tire crumb using a modified gin cylindercleaner (used in the textile industry to remove foreign matter from seedcotton). Partially cleaned crumb is subjected to a second step to removefiber, which can still contain some rubber particles. The resultingcleaned EOL tire crumb is then collected for packaging or other use.See, e.g., W. Stanley Anthony, Applied Engineering in Agriculture, Vol.22(4): 563-570.

American Society for Testing and Materials (ASTM) has standards forspecifying different size ranges of crumb rubber, such as 30 mesh or 80mesh. The range of particle sizes can be determined by sieve analysis,consisting of shaking and tapping a measured quantity of a crumb rubbersample through a specified number of test sieves over a specified time.The amount of sample retained on each screen is weighed and results aregiven as the percentage of sample retained on each screen. Therecommended procedure for sieve analysis using the Rotap method isprovided in ASTM 5644. Typical crumb rubber sizes directed to certainproducts and uses include the following: molded and extruded products,4-100 mesh; asphalt modification, 16-40 mesh; sport surfacing, ¼″-40mesh; automotive products, 10-40 mesh; tires, 80-100 mesh; rubber andplastic blends, 10-40 mesh; and construction, 10-40 mesh.

There are no unified U.S. standards for processing EOL tire rubbercrumb; however, a suitable EOL tire rubber crumb for use in interlinkedsubstitution typically has a low fiber content (less than 0.02% of totalweight), low metal content (less than 0.01% of total weight), highconsistency, and the particles are preferably sized for 100% passthrough 16 mesh. In some embodiments, it may be acceptable to haveparticles of larger size, e.g., 14, 12, or even 10 mesh. For example,10-40 mesh crumb rubber (e.g., 30 mesh, or 25-35 mesh) yieldssatisfactory results when processed according to the methods describedherein. Smaller particles, e.g., 41-200 mesh, can be employed and mayenable more efficient interlinked substitution; however, a reduction inparticle size will incur greater expense in manufacture of the crumb ofthe specified size. Larger particles, e.g., less than 10 mesh (4-9 mesh)can also be subjected to the methods, e.g., for particle size reductionpurposes.

ASTM D5603 Standard Classification for Rubber CompoundingMaterials—Recycled Vulcanizate Particulate, classifies vulcanizedparticulate rubber according to maximum particle size, size distributionand parent materials including whole tires, tire peels, buffingsgenerated from the tire tread and shoulder, buffings generated from tiretread, shoulder and sidewall and non-tire rubber.

End-of-Life Tire Crumb Characterization

EOL tire rubber crumb containing vulcanized rubber and having thedesired particle sizes can be manufactured or obtained from any suitablecommercial source.

As discussed above, the EOL tire rubber crumb is typically of such asize that 100% can pass through a 16 mesh screen, and may further have anarrow size distribution (e.g., no smaller than 20 mesh and no largerthan 16 mesh) or may have a broader size distribution (e.g., significantcontents of fines and various other particle sizes less than 16 mesh).The crumb rubber is typically cleaned of fiber and wire to a purity of99.9 wt. % (i.e., 0.1 wt. % or less of fiber and wire); however, asdiscussed above, in some embodiments such extraneous materials (one ormore of fiber, wire, carbon black) may be permitted to remain present.

If the sulfur content of the EOL tire rubber crumb is unknown,representative samples of the EOL tire rubber crumb can be tested todetermine sulfur content (typically measured in parts per hundredweight), such that a controlled amount of reactant can be used in theextraction process, thereby avoiding overutilization or underutilizationof reactant. However, the methods of the embodiments are generallysuitable for use on rubber possessing any degree of vulcanization, suchthat knowledge of sulfur content is not necessary for processing of thevulcanized rubber. Should it be desired to determine sulfur content, anysuitable method can be employed, e.g., a nitric compound extractionprocess. ASTM D4578 describes standard test methods to apply to rubberchemicals for determination of percent sulfur. These test methods coverthe determination of solvent insoluble materials in a sulfur-containingsample. The two test methods are: (1) Test Method A, Extraction byCarbon Disulfide, and (2) Test Method B, Extraction by Toluene. If thereare no other solvent insoluble materials present in thesulfur-containing sample, the test methods determine the insolublesulfur content directly. If other materials are also present, additionaltesting is necessary to identify what portion of the insolubles (e.g.,carbon black, silica, or other inert fillers) is insoluble sulfur.

Sulfur Crosslinking of Rubber

Elemental sulfur has cyclic eight atoms molecules at room temperature.In the presence of accelerators and activators, elemental sulfurgenerates sulfur fragments that react with reactive groups of rubbers inthe process of interlinked substitution to create cross-links such as:

EOL tire rubber crumb is subjected to a chemical treatment with areactant to induce interlinked substitution. The reactant comprises ametal salt having octahedral molecular geometry and a melting point inthe range of 100−150° C. Examples of suitable reactants include cobaltacetate (CAS 6147-53-1; Co(OAc)₂,) and copper acetate (CAS 6046-93-1;Cu(OAc)₂,), although other reactants can be employed, as discussedelsewhere herein. The reactant is typically employed at from 0.1 to 5.0parts reactant per hundred parts vulcanized rubber (by weight); however,higher or lower amounts may also be employed in certain embodiments. Theamount of reactant employed can be increased or decreased depending uponthe content of sulfur in the EOL tire rubber crumb to be treated, or thedesired degree of interlinked substitution to be obtained. For example,a ratio of reactant molecules to sulfur bonds of 1:1, 4:6, 1:2, or anyother suitable ratio can be employed to achieve a preselected degree ofinterlinked substitution.

Regenerating an Interpenetrating Elastomer Network from Ground TireRubber Particles

In one embodiment, progressive elements are employed to regenerate amonolithic, macro-structural, interpenetrating elastomer networkmorphology from ground tire rubber particles. Element 1 involvesproviding an electro-mechanical reactor environment (EMRE) to supportBoltzman “Phase Space” mediators which unpack the GTRP then realignsulfidic bridge chains for final compounding. Element 2 involvespreparing a GTRP slurry for EMRE processing. Element 3 involvessubjecting GTRP to differential-cyclical mechanical stress and stericelectro-polarization. Element 4 involves subjecting the GTRP slurry toengineered, cavitation-induced thermal and acoustic shockwaveexcursion(s). Element 5 involves generating a chemotactic,sulfidic-bridge-tether-effect. Element 6 involves production of chemicalreaction products and timeline. Element 7 involves compoundingregenerated GTRP into a fully-integrated, monolithic, macro-structuralelastomeric material.

In Element 1, an electromechanical reactor environment (EMRE) providesan effective “Phase Space” environment to 1) unpack the GTRP and resetthe vulcanization precursor for 2) subsequent sulfidic bridgerealignment, 3) with minimal alteration to the native, elastomer-fillermatrix. FIG. 1 an EMRE head. The head comprises a 16 inch stainlesssteel rotor 101 with a variable tip speed and maximum 15,000 fpm. A 17inch stainless steel stator 102 is also employed having a hundred andten slots (cavitation portals) 103. The components generate a GTRPslurry flow pattern 104 as depicted in FIG. 1. In FIG. 1, detail of thecross-section along line ‘A’ is provided. While an EMRE as depicted inFIG. 1 can be advantageously employed, other mechanical platforms may beconfigured as reactors employed in the methods of the embodiments, e.g.,progressive cavity pumps, screw pumps, extruders, or the like.

In Element 2, the GTRP slurry is prepared. FIG. 2 depicts a processschematic for this process involving a stainless steel mix tank 201containing a submerged EMRE head 202. In operation, the tank isgenerally filled to about 70% of the available tank volume. The slurryis prepared from EOL whole tire that has been subjected to conventionalprocesses to remove metal and fiber, and is ground to pass through a 30mesh (600 micron) sieve. In the example process depicted in FIG. 2, a300 gallon stainless steel mix tank is employed to produce a 200 gallonbatch of EOL tire rubber slurry having a specific gravity of 1.03. Thestainless steel tank can be non-insulated to allow dissipation of EMREenergy (thermal energy). In certain embodiments, cooling coils can beadded to permit the batch temperature to be maintained below a boilingtemperature or, alternatively, the process tank can be sealed to allowoperation at higher temperature under pressurized conditions. The batchof EOL tire rubber slurry weighs 1716 lbs when a 3:1 ratio of water toGTRP. The components of the slurry in FIG. 2 include approx. 152 gallonsof reverse osmosis (RO) water, approx. 400 lbs of GTRP, and approx. 8lbs of copper acetate (referred to as organometallic compound or OMC)predissolved in approx. 40 lbs RO water. Filtered water recovered from aprevious batch, including water squeezed out from a filter cake, can beused as a portion of the approx. 152 gallons of water used to prepare abatch. It is generally preferred to use fresh RO water for dissolvingthe OMC; however, in some embodiments recovered water can also beadvantageously employed.

In Element 3, the GTRP of the slurry traverses a “Phase Space Tunnel”where differential-cyclical mechanical stress and steric fieldpolarization are applied to the GTRP. The concept of “Phase Space”depicted herein (sometimes referred to as a Tunnel) was first put forthby Boltzman as a “box” in which molecular structures and velocity arequantified against a time interval when the “contents” of the boxundergo outside influence(s). When the “box” environment is induced withentropy-enthalpy-entropy phase changes in short,time-oscillating-intervals, enormous energy forces (velocity) areunleashed within the “box”. This process is schematically depicted inFIG. 3A, with linear distance, GTRP geometry, velocity, and accelerationprofile depicted as a function of time over a timeline extending from0.000 sec. to 0.0019 sec. Time 0.000 is when the particle impinges uponthe EMRE rotor 301. The GTRP is then subjected to compression in thestator (compression gate 302), exits the stator, and enters into arecirculation pattern. As depicted in FIG. 3B, the space between theEMRE rotor 301 and the exit of the compression gate 302 is referred toas the Phase Space Tunnel 303. A modulated AC current can optionally beapplied at the compression gate to facilitate the process. Electrodes304 are provided that introduce a modulated AC current. From 0 (or nooscillation) to 100 Hz oscillation can be applied, or oscillation up to1000 Hz or more can be applied by employing a frequency controller.Voltages up to 300 V or more can be applied to induce current flowacross the slurry medium, which has the effect, through the rapidreversing of polarity, of depositing electrons upon the surface of therubber particles in the phase space tunnel. The process of compressionin the stator deforms the GTRP such that the ratio of width to lengthincreases to 6:1. The “trampoline” effect of rapidcompression-stretching-decompressing assisted by a modulated, AC currentflow across the stator slot, enhances the steric effect of repulsionbetween overlapping electron clouds with subsequent accelerateddelamination of the GTRP bound matrix, as depicted in FIG. 3C. For a 600micron particle with approximately 1200 transverse sulfidic crosslinks,60 dislocated and repotentiated vulcanized precursor sites areregenerated per pass through the stator. It is noted that the EMREdepicted in Element 1 is an embodiment of the Parallel Continuous FlowMicro-synthesis Reactor (PCMR) hardware described elsewhere herein,principally as it avoids the necessity of building and certifying apressure vessel for conducting the process of the embodiments. However,the PCMR, operating at a fixed temperature along a water-to-steam curveis able to produce similar “Phase Space” particle-unpacking results withthe GTRP as the Element 1 EMRE embodiment in the five quanta of“Timeline”, “Linear Distance”, “GTRP Geometry”, “Velocity” and“Acceleration Profile” depicted in FIG. 3A by pushing the GTRP slurrythrough strategically positioned, mechanically larger diameter apertures(e.g., an adjustable iris valve) which allow the slurry volume toexpand, whereupon it goes into a gas phase, then be immediately reducedback to the original, internal pipe diameter. With the slurrytemperature versus pressure induced to oscillate in and out of asteam-liquid-steam cycle, GTRP unpacking efficiencies are equivalent.With each pass through the rotor, particle size is reduced. At areduction to a size of 200 mesh (70 microns), approximately 65% of thecrosslinking bonds are disrupted, and the particles may be mechanicallyleafed into thin, pancake-like structures (e.g., ‘smeared out’ into a 10micron film). Further size reduction is typically not sought after. At areduction to 5-60 microns, carbon black starts to come out of theparticle matrix. At a reduction to a size of 5 microns, reduction ofcarbon begins to occur. A particle size of 200 mesh (70 microns) isgenerally useful for most applications, such as tire, roofing, andpaving applications; however, in some embodiments sizes down to 10micron can be desirable.

In Element 4, an engineered, cavitation-induced, acoustic shockwave isapplied to the GTRP. As shown in FIG. 4A, in the phase space tunnelbetween the EMRE rotor 401 and the compression gate 402, a mixture ofGTRP 405, entrained air 406 and an aqueous organometallic compoundmatrix 407 is present at a velocity and volume. Upon exit through thecompression gate 402, air bubble compression and particle accelerationcreates a cavitation progression 408. As the slurry exits, lowerpressure completes the cavitation cycle with an implosion of aircavities. It is generally preferred that no bulk-phase change occurwithin the continuous water phase of the slurry during cavitation.Therefore temperature and pressure differential excursions take place onan atomic scale. This process generates extreme temperature and pressuredifferential excursions within the nano-regions, cavitation cone in arange of 10²° F.-10¹⁵° F. for temperature, 60 m/sec-180 m/sec foracoustic wave velocity, all occurring over a time interval of 10³sec⁻¹-10⁸ sec⁻¹. By changing the rotation speed of the EMRE rotor and/orslurry viscosity and/or stator gap, manipulation of energy “leverage”within the phase space tunnel can be accomplished. FIG. 4B depictsprocess control variables for the GTRP slurry and EMRE. Aproportional-integral-derivative controller (PID controller or threeterm controller)—a control loop feedback mechanism widely used inindustrial control systems and a variety of other applications requiringcontinuously modulated control—is employed to control temperature,aperture size, the volume of the slurry, and oscillation between vaporand liquid. Other factors that can be adjusted, e.g., by PID controller,related to the reactants include the ratio of rubber to water, the OMCadded (amount, rate of metering, intermittent or continuous metering),the amount of OMC residue, the rate of reduction. Apparatus relatedfactors that can be adjusted, e.g., by PID controller, include the rotortip speed and the gap size between the EMRE and the compression gate.FIG. 4C provides a table including a list of selected GTRP slurrycontrol variables and results of modifying them. FIG. 4D provides atable including a list of selected EMRE process control variables andresults of modifying them.

Element 5 illustrates a chemotactic sulfidic-bridge-tether-effect (SBTE)dynamic. FIG. 5A depicts the original sulfidic bridges schematically,including formation of pendant vulcanizate precursors that occurspredominantly at a methyl carbocation (originally forms at approx. 140°C.) and completed vulcanization that occurs primarily at an allyliccarbocation (subsequently forms at approx. 160° C.). FIG. 5B depictstypes of carbocations (with varying numbers of carbon atoms attached tothe carbocation) in order of stability, with tertiary carbocations themost stable, secondary carbocations less stable, primary carbocationseven less stable, and a methyl carbocation the least stable. Resonanceadds stability to allylic carbocations as positive charge density isspread out, making it more stable than a secondary carbocation asdepicted in FIG. 5B. The process of sulfidic bridge dislocationtherefore preferentially occurs at a methyl carbocation rather than atan allylic carbocation. The result of the dislocation is that the rigidsulfidic bridge becomes a tether connected at the original allyliccarbocation and becomes unbound at the methyl carbocation.

In Element 6, the chemical reaction occurs along a timeline. The ROwater and OMC (in this case metal acetate or MOAc) in a 20% solutionconcentrate is mixed and metered into the GTRP slurry (180° F., 3:1ratio by weight of RO water to GTRP), as depicted in FIG. 6A. Theresulting chemical reaction is depicted in FIG. 6B. The organometalliccompound dissolved in water associates with ligands, including transientaquo metal formations. In FIG. 6B, k refers to the Boltzman “phasespace” EMRE tunnel mechanistic-kinetics, M²⁺ refers to the metal ion;NH_(n), CH_(n), Zn_(n) and S_(n) refer to what are believed to be isomer‘debris’ near the precursor site that are byproducts of the originalrubber compounding process, and OAC⁻² refers to the acetate ion. Theoriginal tire vulcanization precursor, allylic hydrogen, scavenged bythe MBTS amine group, previously described, forms reaction by-products.Nitrogen-sulfur compounds include ammonium disulfate (NH₄)₂S₂O₈molecules (ADS), or radicals thereof, which reside and are compacted asdebris isomers, proximate to the methyl carbocation. Thesenitrogen-sulfur isomers, which notably are not created during the finalstep of the original sulfidic-vulcanization at the primary carbocationof the sulfidic-crosslink upon the adjacent polymer chain, are highlysoluble in water and become powerful oxidizers to drive the methylcarbocation substitution sulfidic-metathesis. The active OMC, a metalcoordination complex, may either activate a hydration of the ADSmolecule forming hydrogen peroxide (H₂O₂) and/or become an accelerant toenhance that reaction in its targeted, metathesis action as an oxidizerin the methyl carbocation. The sulfidic-metathesis conversion rate atthe methyl carbocation is assured without any peroxide and/or otheroxidizer when the temperature threshold at the reaction site is greaterthan 240° F., above which the sulfur becomes labile in phase change.This may be induced by either a pressurized, phase change oscillationfrom water-to-vapor or a sudden, phase-space-cavitation implosion withbursts of hyper energy that result in a solid-to-liquid-to-solid phasechange of both the sulfur and OMC compound at the methyl carbocationtarget site. To more fully appreciate the enormous energies released bythe imploding cavitation cone, recent CERN studies on the subject haveproposed that an electromagnetic plasma entanglement is formed duringthe pico-second deformation that is quite similar to the phenomenaassociated with the 300-times greater solar corona temperature ascompared to the sun's surface. Following this analogy, for a 180° F.GTRP slurry, passing through the Phase Space Tunnel, the pinpoint,cavitation temperatures at the target methyl carbocation site would beexpected to be, at a minimum, 54000° F. for a very brief moment.

While not wishing to be bound by any theory, it is believed that in thereaction, metal acetate ion dissociative substitution occurs at themethyl carbocation. This disrupts the vulcanization precursor, and theinsertion forms a new functional site at the elastomer pendent structurefor subsequent sulfidic bridge realignment. In the process, O²⁻ isconverted to CO₂ with a phase space particle charged carbon aggregate.Strong interactions between M²⁺ and S²⁻ form a precipitate, whichliberates a rigid sulfidic bridge to a ‘tether’ state, bound only at theoriginal allylic carbocation. Various metal ions are suitable for use,including but not limited to Co²⁺ (ligand exchange rate for an H₂O metalcoordination matrix of 3×10⁶), Cu²⁺ (ligand exchange rate for an H₂Ometal coordination matrix of 5×10⁹), Ni²⁺ (ligand exchange rate for anH₂O metal coordination matrix of 3×10⁴), Zn²⁺ (ligand exchange rate foran H₂O metal coordination matrix of 2×10⁷), and Mn²⁺ (ligand exchangerate for an H₂O metal coordination matrix of 2×10⁷). Substantial dataexists in literature that a copper based organometallic molecule canmanifest up to a coordination number of ten (10) in a heated, waterenvironment. This coordination capacity provides for the intermediateformation of a super-floppy matrix to assist the process by capturing aligand from the inhibiting isomer ‘debris’ near the methyl carbocationreactive site. The ligand capture and release rates are many timesfaster than other metals as well. These impressive capabilities lead tothe possibility that a variety of copper based, reaction isomers may becreated from the heterogeneous maw of molecules present during the GTRPunpacking-metathesis sequence. By selecting an organometallic compoundthat exhibits a phase change at a temperature close to that of elementalsulfur, it may be possible to facilitate the metathesis reaction;however, organometallic compounds having different phase changetemperatures can also be employed.

In Element 7, fabrication of a monolithic, rubber macrostructure occurs.FIG. 7A depicts the macrostructure of ground state vulcanized GTRP(Stage 1), EMRE conditioned GTRP (Stage 2) including unbound,pre-reptated internal morphology, and regenerated interpenetratingelastomer network (Stage 3) which includes intermingled laminates spacedapart by 10 nm to 5 microns. One of the features of the process of theembodiments is that crosslinks are reestablished in the interpenetratingelastomer network by a gentle process that leaves carbon blackundisturbed. This yields a slight reduction in tensile strength, but animprovement in rebound strength.

In the fabrication process, as depicted in FIG. 7B, the processed GTPRslurry is pumped off and through a filter cake press, the spin dried toa moisture content of less than 1% by weight. The resulting processedGTRP can be oven dried in a tumble dryer to a moisture content of lessthan 0.1% by weight to yield a dry, EMRE-conditioned GTRP. Between thepress filter step and the tumble dryer step, select waterborne orliquefied thermoplastic virgin polymers can optionally be wet blendedinto the processed GTRP. The dried GTRP can be subjected to an internalmixer (e.g., a Banbury mixer, a sigma blade, or the like) and/or a rollmill for micro-laminate, where dry, EMRE-conditioned GTRP is blendedwith polymer and crosslink additives. The resulting product can then bepackages as pellet, roll, block, festooned sheet, or the like. Incertain embodiments, the processed GTPR slurry is a valuable product foruse without any further processing steps. The GTRP can be mixed withasphalt to form rolls and sheeting, or melted to bind aggregate, or toform an emulsion. Similarly, product in any of the intermediate steps inElement 7, including press filtration, tumble drying, wet blending,internal mixing, and packaging can be a valuable product in its ownright. Accordingly, any of the steps of Element 7 can be consideredoptional in various embodiments. It is noted that when a roll mill isemployed, the resulting GTRP is ‘leafed’ into thin pancake-likestructures that will form during subsequent vacuum forming, impartinganisotropic properties to the resulting GTRP sheet. When an internalmixer is employed, resultant sheets made therefrom are substantiallyisotropic.

A mixture of asphalt and GTRP can be prepared by various methods. As afirst step, GTRP is run through a finishing roll mill until a ‘leafed’or ‘fully leafed-reptated’ form is obtained (having, e.g., an approx. 10μm or smaller particle thickness in the smallest dimension), and thenroll-mill or internal mixer combined with asphalt. Typically, a cohesiveGTRP sheet (indicative of a ‘leafed’ form) can be obtained after 10passes through a finishing roll mill with cold rolls, or 2 passesthrough a finishing roll mill with hot rolls. Once a cohesive GTPR sheetis formed, it can be combined with asphalt. In one embodiment, asphaltis added to the cohesive GTRP sheet on the finishing roll mill, thenmixed in by action of the finishing roll mill to yield a mixture of 92%by weight GTRP and 8% by weight asphalt in the form of a continuousGTRP/asphalt sheet. Type IV asphalt can advantageously be employed;however, an asphalt in a 5 pen to 200 pen range can also be employed. Acrosslinking agent can optionally be added with the asphalt (e.g., 0.005phr (parts per hundred) of the continuous GTRP/asphalt sheet). The sheetcan advantageously be turned during the process to facilitate a uniformdistribution. A cohesive GTRP sheet (‘leafed’) or continuousGTRP/asphalt sheet can be further combined as hot melt with asphalt inany form, e.g., particles, emulsion, or hot mix. Revulcanization canadvantageously be accomplished after the GTRP/asphalt blend is in situinstalled.

In paving applications, for example, a cohesive GTRP sheet or continuousGTRP/asphalt sheet can be melted into asphalt to yield a compositioncomprising from about 20-50% by weight GTRP, e.g., suitable for use as abinder for aggregate. In another example, the continuous GTRP/asphaltsheet can be applied in sheet form to a damaged pavement, thenconventional hot mix, aggregate, or a mixture of aggregate and bindercan be applied as a top layer on the continuous GTRP/asphalt sheet.Irradiation can advantageously be applied to induce crosslinking andbinding of the GTRP. When employed in asphalt as a binder, or in anunderlayment comprising a continuous GTRP/asphalt sheet, the GTRP canadvantageously be cured in place on the road bed using an emitter systemand associated apparatus and methodology as described in U.S. Pat. Nos.8,992,118, 9,169,606, 9,074,328, 9,347,187, 9,481,967, 9,551,117,9,551,114, 9,624,625, 9,637,870, 9,127,413, and 9,057,163, the contentsof each of which are hereby incorporated by reference in theirentireties. Such an emitter system for irradiating asphalt/concretepavement typically includes a structural frame holding an emitter panelconfigured to emit a peak wavelength of radiation of from 1000 to 10000nm to achieve flux of the asphalt in the asphalt/concrete pavement. Theterms “flux” or “fluxing” as used herein are broad terms, and are to begiven their ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customizedmeaning), and refer without limitation to describe a fluid that isdisplaceable by application of minimal pressure against a body of thefluid. Temperatures in a range as high as 190° F. to 290° F. (88° C. to143° C.), e.g., 250° F. to 290° F. (121° C. to 143° C.) canadvantageously be employed to induce flux of asphalt. For irradiation ofGTRP to induce crosslinking, radiation having a peak wavelength in arange of 350 nm to 700 nm peak can advantageously be employed, and canbe used in addition to radiation having a peak wavelength of 1000 nm to10000 nm (e.g., two peak wavelengths). Some degree of crosslinking willoccur in the absence of the addition of crosslinking agents; however,additional crosslinking agents can boost the speed and efficiency of theprocess. It is noted that a temperature of 170° F. can inducecrosslinking when DIBP is employed as a crosslinking agent, making itadvantageous for use in GTRP/asphalt sheet where stability andcontrolled crosslinking is desired. When dicumyl peroxide is employed asa crosslinking agent, crosslinking will rapidly occur even the absenceof applied heat. Dicumyl peroxide can be advantageously employed as acrosslinking agent when the GTRP/asphalt is in liquid form (e.g.,emulsion). Paving material comprising GTRP exhibits superior propertiesin terms of longevity when compared to conventional paving materialsincluding ground tire rubber that has not been subjected to anytreatment.

The continuous GTRP/asphalt sheet can be used in the form of rolls andsheeting for weatherproofing or roofing applications. Alternatively, thecohesive GTRP sheet (‘leafed’) or continuous GTRP/asphalt sheet can bemelted into asphalt or another solvent and the resulting mixture appliedto a surface by spraying, yielding a sealed and waterproofed surface.The resulting rubber particulate is also of a quality suitable for usein house shingles and roll roofing, offering hail damage resistance,improved cold temperature flexibility (e.g., flexibility down to atemperature of at least −40° F.), and reduced softening, bleed out andstaining in hot weather. The roll roofing containing rubber particulatecan be placed dry and then subjected to irradiation, causing the sheetto melt, conform, crosslink, and adhere to an underlying substrate(e.g., insulation or old roofing). A liquid mixture containing GTRP canbe subjected to irradiation to induce crosslinking. Irradiation can beapplied using an emitter system similar to that described above forpaving applications (e.g., U.S. Pat. Nos. 8,992,118, 9,169,606,9,074,328, 9,347,187, 9,481,967, 9,551,117, 9,551,114, 9,624,625,9,637,870, 9,127,413, and 9,057,163, the contents of each of which arehereby incorporated by reference in their entireties). Electromagneticradiation of a preselected peak wavelength can be applied to the roofingor waterproofing sheet or spray in place. The heating radiation can begenerated by modifying an emitter to emit a desired wavelength. Thewavelength of the electromagnetic radiation used for heating is selectedbased upon the materials present in the roll roofing. Preferred peakwavelengths for targeting rubber in the roll roofing are in a range of350 nm-700 nm peak wavelength at watt densities of less than or equal to10 watts/in². The radiated energy applied to the roll roofing heats therubber in the roll roofing while minimizing heating of the substrate.The emitter device can be manufactured to minimize cost and are suitablefor use in the field. Field use can be achieved by powering the deviceusing a portable generator, e.g., a Tier 4 diesel engine, electricallyconnected to one or more emitter panels situated within a metal frame.The emitter can be insulated with, e.g., a high-density ceramic, and thepanel(s) can be nested within the ceramic liner of a frame to pointtowards the plane of the roll roofing.

Drying of the post-reactor GTRP blend can be conducted to any desireddegree. Moisture can be removed slowly or quickly. Gentle drying willhave minimal impact on the structure of the elastomer networkmorphology. Drying with shear typically yields smaller particle size andquicker evaporation of moisture.

Curing of the post-reactor GTRP blend can be conducted slowly orquickly, by use of chemical curing agents, or by irradiation (e.g., byan emitter system as discussed elsewhere herein).

In some embodiments, it can be desirable to combine dried post-reactorGTRP with a solid polymer (e.g., virgin rubber) by dry blending, thensubjecting to further processing to mix the components. Alternatively, alatex with a certified number of reactive sites can be combined with thepost-reactor GTRP and subjected to further processing. Water can laterbe removed, e.g., by squeezing. Post-reactor GTRP can be modified forvarious uses, e.g., as a thermoplastic, thermotrope, or thermoset. Thepolymer backbones are predisposed for vulcanization. Because thepost-reactor GTRP is hydrophobic, hydrophilicity is imparted to thematerial to permit it to be emulsified or formed into a colloidalsuspension. Properties can be modified by adding a homopolymer tofunctionalize the backbones. To impart thermoset properties, theparticles can be coated (e.g., with nonylphenol ethoxylate). To impartthermoplastic properties, hydrophilic sites can be inserted (e.g., withquaternary amine).

As discussed herein, subjecting GTRP to oscillation across thesteam/water phase pumps liquid into the caverns of the particles. Thiscan saturate the parties very quickly, e.g., less than one minute.During the reactor process, water can inundate the particle such that alarge increase in free molecular space is observed, e.g., 500% or more,e.g., a five-fold increase. This results in a dried particle that can bedescribed as “fluffy”. Dried GTRP possess “caverns”—internal spaces(free molecular spaces) that can accommodate liquids. Application ofshear forces to GTRP can collapse these caverns. When GTRP is providedas a colloidal suspension with a material to be mixed, the presence ofcaverns facilitates internalization of materials in a liquid in thecaverns of the GTRP. Such materials can include waterborne polymers.This can result in superior polymer dispersion properties compared toconventional solid upon solid mixing as is the primary method of polymerblending in the tire industry, for the resulting particle, e.g.,superior tensile strength, hysteresis, and shear. An improvement inphysical strengths of 200-300%, or more, from what is observed in rubbertypically utilized in the tire industry can be observed.

Based upon physical property analysis of samples composed ofpost-reactor GTRP blends with small quantities of virgin, styrene,1,4-cis polybutadiene polymer, greater than approximately 80% crosslinkdensity, as compared to a virgin, tire-grade, black master batchcompound, can be regularly achieved using a dicumyl peroxide (DCP)catalyst cured for two hours at 240° F. DCP provides reactive crosslinking below 240° F. but curing temperatures above that thresholdliquefies the tethered sulfuric chain such that its labile state willmore efficiently complete the re-alignment. Another effectiveaccelerator is di(tert-butylperoxyisopropyl)benzene (CAS No. 25155-25-3,also referred to as DBPI).

Silicone rubber (SiR), grafted with a 1,2-high vinyl butadienehomopolymer functionality, may be cross linked with mercapto groupcatalyst. Such blends will result in high crosslink densities anduniform, elastomer, interpenetrating domains which exhibit superior,hybridized properties known to both rubber groups. An NR/SBR blackmaster batch SiR hybrid, using a regenerated EOL particle is a new, costeffective innovation.

In another embodiment, GTRP particles are size reduced and crosslinkrealigned in an anhydrous environment. EOL tire rubber crumb ispreheated to a temperature of about 250° F. (e.g., 230° F. to 270° F.,or 240° F. to 260° F., or 245° F. to 255° F.) in a three shaft verticalmixer or other suitable mixing apparatus. The reactant (e.g., copperacetate or other metal salt as described herein) in solid form ispreheated to a temperature of 250° F. (e.g., preferably above the metalsalt's melting point, e.g., up to 250° F. or more, e.g., 230° F. to 270°F., or 240° F. to 260° F., or 245° F. to 255° F.) in a separate vesselunder inert atmosphere (e.g., nitrogen blanket). In certain embodiments,the inert atmosphere can be optional. The heated reactant is combinedwith the pre-heated EOL tire rubber crumb. For example, the heatedreactant can be sprayed, misted, or poured into the pre-heated EOL tirerubber crumb under agitation to achieve uniform coating and distributionof the reactant on the pre-heated EOL tire rubber crumb, yielding anactivated EOL tire rubber crumb. When added directly to the pre-heatedEOL tire rubber crumb, the reactant can advantageously be provided inthe form of a finely ground powder.

Applications for Interlinked Substituted Rubber Material

As discussed herein, the interlinked substituted rubber material of theembodiments is suitable for use in a wide variety of applications,including the tire and paving applications discussed above, or any otherapplications wherein virgin rubber would be employed. By using various,reactive adhesive matrices, e.g., hot melts (e.g., asphalt, SBR,polyisobutylene (PIB), and polyethylene (PE)) and multicomponentreactives (e.g., fatty acid based polyols), artifacts have been made andthe properties have been evaluated. These properties suggest that thecompounded interlinked substituted rubber material can effectivelycompete with much more expensive silicone, urethane, epoxy, andethylene-propylene-diene terpolymer (EPDM) based materials at a fractionof the cost. The compounded interlinked substituted rubber material iswaterproof, exhibits lightweight structural properties, is abrasionresistance, resists exposure to salt, common chemicals, and hydrocarbonbased fuels, and exhibits superior thermal and UV resistance. Aninterlinked substituted rubber material having properties tailored for aparticular application can be obtained by adjusting the process dynamicsassociated with the entangled polymer-nanoparticle composite that is theinterlinked substituted rubber material. For example, in some instancessmaller particle size is not necessarily desirable, and there arecertain morphological features as described herein that can providesuperior performance to virgin rubber. The nano-particles have aprofound effect on the mechanical properties of the polymer; therefore,controlling the in-service, entropic-enthalpic interaction of the hostpolymer chain motion (constraint and relaxation), in all time-scales,can provide many benefits.

It is observed that interlinked substituted rubber material performanceattributes can precipitously drop with a particle size reduction below adimension which is less than about 5-10 times the random coil radius ofthe host polymer. This is based upon a model where the original compoundfrom the ground tire generally has a nano-particle cluster:polymer,random coil ratio bias (in favor of the polymer) of greater than1.0:1.0.

The over two hundred elements that go into making a tire may be manifestat greater than 90% (as element count) of the mass of individual GTRparticles, suggesting that characterizing uniformity of the interlinkedsubstituted rubber material may not be possible, but this is not so. Thedependable method for abrogating sulfidic influence as in the methods ofthe embodiments is deliberately ‘gentle’ upon disrupting the chemicaland intermechanical properties of the composite and a system forclassifying uniformity is in development. The composite, viscosityobservational puzzle(s) which contradict the Einstein-Batchelorviscosity law will have a partial resolution once the sulfidic componenthas become non-influential. As a simple method of characterizing theresultant process yield by correlating optimal, process intensity andarticulation emerges, it is expected that the interlinked substitutedrubber material can be employed in a variety of products, including highperformance applications. Examples for high performance applicationsinclude in-situ, monolithic, structural, self-insulating, foamed panels.Dried and ground, indigenous carbonaceous, cellulose rich vegetation maybe chopper-gun formed with the regenerated GTR as a principal binder (athigh loadings) into small, permanent, earthquake proof habitats.Secondary containment spray applied membranes may be installed in tanksand ships. Robot-sprayed, plural component, chemically resistant andpressure stable linings may be installed in aging sewer and water pipeswithout excavation. UBC compliant, monolithic roofing membranes may befactory manufactured membranes or sprayed in-place. New civilinfrastructure underground piping may be protected with more durablecoatings derived from interlinked substituted rubber material. Marinestructures of all types may be corrosion protected with anti-fouling,PTR-based, composite coatings. Almost any article being currentlyproduced which must be insect and vermin-proof, fuel-proof, mold andbacteria-proof, sun and salt-proof can be manufactured for superiorperformance with an interlinked substituted rubber material-based shell.

Re-Engineered Elastomeric Polymer Synthesis

A re-engineered, elastomeric polymer (REEP) which has been previouslycross linked with sulfur compounds requires a disruption of the sulfurlink and an insertion of alternative chemistry if it is to enhance thefinal properties of the composition into which the REEP is targeted asan essential element. Such polymers can include, e.g., ground tirerubber, rubber of another source, other elastomers such ascis-1,4-polyisoprene, trans-1,4-polyisoprene, natural polyisoprene,synthetic polyisoprene, polybutadiene, chloroprene rubber, halogenatedbutyl rubber, nonhalogenated butyl rubber, styrene-butadiene rubber,hydrogenated nitrile rubber, nonhydrogenated nitrile rubber, or otherunsaturated rubbers capable of being cured by sulfur vulcanization orhaving carbon-sulfur bonds in the polymer's backbone, e.g., —C—Sn—C,where n is an integer of two or more. Re-crosslinking enhances oxidationresistance and mechanical properties, thereby improving thestress-relaxation and/or performance spectrum. The final, re-crosslinked properties of the REEP may advantageously impart a thermosetting(rigid) or thermotropic (elastic) character to the completedcomposition. Beneficial reptation (elastomeric polymer relaxation)during the processing of a REEP is more readily accomplished during theintra-cross link manipulation stage as well (e.g., in conjunction withinterlinked substitution as described herein).

Sulfur vulcanized REEPs predominantly consist of polysulfidic bridgeswith bond energies of approximately 150 kJ/mol. Reducing these bridgesto a mono- or di-sulfidic state substantially improves the oxidationresistance of the host elastomer, as the bond energies of mono- ordi-sulfidic bridges are approximately 270 kJ/Mol. Employing a one-step,‘click’ metathesis wherein the sulfur bond is hybridized is a desirablestep in preparing the REEP for final compounding into anelastomer-containing product.

Utilizing a Parallel, Continuous-flow, Micro-synthesis Reactor (PCMR) toconduct a single-pass, molecular re-assembly of a REEP can be based on areal time insight into the effectiveness of the reduction-substitutioneffort within the developing polymer morphology if it is to yielddesired, post-reactor, dynamic mechanical analytics. Interacting polymerdipole moment within thin, “on-the-fly”, loop delayed, cross sections ofthe reactor flow to an external, modulated electrical field, whilecapturing both permittivity and the field, curl gradient deviations,provides pinpoint differential data as to the changes taking place as aresult of up-stream dosing stations. It also provides essential,intervention directives as to what additional electro-chemical ‘inputmenu’ might be required to achieve desired, final properties as thepolymer completes the PCMR progression. Similar advantages can beascertained within a PCMR environment by the utilization of curlgradience amplification (CGA) technology.

FIG. 8A depicts a PCMR of one of the embodiments that utilizes aloop-molecular assembly propagation (L-MAP) process by curl gradienceamplification. The L-Map Process as described herein integrates CGAtechnology into an advanced, modular, PCMR platform that possessesunequalled capabilities to create novel as well as re-engineeredpolymers. The reactor includes a turbo integrator 802 into which meteredcomponents 801 are added. These components can include monomers,homopolymers, polymers, and/or other components. In the embodimentdepicted, an interlinked substituted rubber can be added to the turbointegrator along with other components for modification of theinterlinked substituted rubber, e.g., one or more monomers, oligomers,or polymers to be grafted onto the interlink substituted rubber, or oneor more reactants to functionalize the interlinked substituted rubber(e.g., end capping of a polymer chain, ionic substitution, etc.). In theembodiment depicted, the mixture of components is heated to 180° F. andfed into a specialty pump 803 (Specialty Pump #1). The pump depicted isconfigured to operate at pressures less than or equal to 100 psi, and attemperatures less than or equal to 360° F.; however, if higher pressuresand/or temperatures are desirable for the particular mix of componentsbeing processed, then a different pump meeting the required pressure andtemperature specifications can be substituted. The mixture is then fedby the pump into a bank of pipe 804. To minimize the footprint of thebank, the pipe is shaped in a serpentine configuration, and has a totallength of 800 inches. The embodiment depicted includes stainless steelpipe 4 inches in diameter, which is configured into a bank of ten loopedpipe segments, the bank having a length of 120 inches. As the mixturepasses through the pipe, the components of the mixture react, yielding are-engineered, elastomeric polymer having a preselected composition andproperties. The output of the pipe is directed to a second pump 805(Specialty Pump #2), which pumps the reacted mixture to a drying tank806 for liquid recovery (e.g., at 205° F.). The configuration depictedin the embodiment is capable of outputting 783 gal/hr of slurry 807 whena set of two banks are employed. The reactor can be scaled to anysuitable configuration. For example, one or more turbo integrators orother mixing devices as are known in the art can be employed, optionallywith heating or cooling capability, pressurization, or maintenance of aninert atmosphere. A single turbo integrator can supply one or morebanks, or multiple turbo integrators can supply a single bank. One ormore pumps can be employed, either in serial to a single bank, inparallel to a single bank, or a single pump can provide multiple bankswith appropriate piping or valves. As discussed above, the pumps can beselected based on the desired properties of the mixture to be pumped(temperature, pressure, etc.). In certain embodiments, the mixture fromthe bank may be employed directly in subsequent processes (e.g.,omission of Specialty Pump #2 and/or drying tank from the reactor).While 4 inch stainless steel pipe is employed in a bank, other diameterscan advantageously be employed, e.g., 0.25 inches or less to 6 inches ormore in diameter, and any suitable pipe length can be employed thatallows the components of the mixture sufficient residence time to reactto produce a preselected product, e.g., 50 inches or less to 2500 inchesor more. In some embodiments it may be desirable to operate multiplebanks in a serial configuration, optionally with a pump situated betweenthe banks, e.g., so as to permit longer residence time or use of pumpscapable of operating on a reduced pressure. The pipe(s) can be fittedwith strategic static mix and chemical injection points to facilitatereaction 804A (FIG. 8A, Note 1) and integrated curl gradienceamplification (CGA) ports 804B (FIG. 8A, Note 2). The pipe(s) can alsobe, partially or entirely, in a controlled thermal space, e.g., aheating or cooling jacket or temperature controlled immersion bath canbe employed. Alternatively, the pipe(s) can be exposed to ambientconditions.

FIG. 8B depicts a space saving tube configuration. In thisconfiguration, the tube 811 is spiraled, and can be in a controlledthermal space 810. This spiral tube configuration can be extend along anaxis from the inlet end 811A to the outlet end 811B, or can be furtherconfigured into a serpentine configuration of spiraled tube to reducethe footprint of the bank even further.

The PCMR of the embodiments can advantageously be employed tofunctionalize or react interlinked substituted product as describedherein in a manner similar to how virgin rubber is reacted orfunctionalized. Graft polymerization, chain end functionalization, andthe like can be conducted. The resulting products can be made suitablefor use in asphalt binder, tire rubber, specialty rubber products, andthe like.

Morphology of PTR

The product streams generated by a method conducted in an alternatebatch mode process utilizing a stirred pressure vessel were observedafter numerous runs. It was observed that tiny, golden fibers with across section of about 0.002 inches-0.005 inches, and of a variablelength, were present within the interlinked substituted rubber material.The fibers are expected to only be destroyed by excessive heat(temperatures higher than those employed in the interlinked substitutionprocess described herein, and higher than those characteristic of hotmix processes) and will not dissolve in trichloroethylene (TCE).

The fibers' presence can be expected to not add significant mass to theinsoluble component of the sub-micron interlinked substituted rubbermaterial but it is expected to plug a one-micron filter pore, making theactual filter medium less porous, and thereby leading to a false readingof the filtrate concentration quanta. Samples of interlinked substitutedrubber material in a form of a slurry were passed through a hightemperature-high pressure piston-diaphragm pump and through a highstrength, sintered filter capable of handling up to 50,000 psi through a1.0 micron orifice. This further processing, which is believed to reducethe overall length of the fibers, yielded a smooth mixture capable ofpassing through a one-micron filter pore. The further processing readilydisintegrated the rubber into an easily dispersible, sub-micron moiety,with some release of carbon black.

This fiber component derived from recycled tire may greatly improve thestrength of the bond between the asphalt to which the interlinkedsubstituted rubber material is added (e.g., as a binder or adhesive) andthe aggregate, thereby improving overall pavement performance, yieldinga superior pavement when compared to one prepared from aggregate andasphalt containing virgin rubber.

PTR in Black Master Batch

Interlinked substituted rubber material, generated using lab scaleequipment analogous to the apparatus depicted in FIG. 1 under conditionssimilar to those set forth in FIG. 2, was added to a known-property baseblack master batch of virgin rubber at an amount of 10 wt. %, (afteradjustment for filler materials in the interlinked substituted rubbermaterial). The resulting 10 wt. % mixture was subjected tothermogravimetrical analysis and other testing. The resulting 10 wt. %mixture was observed to be near-equivalent in homogenizable, physicalproperties to the known-property base black master batch of virginrubber, such that it will not affect the final performance of a newtire, or can be used in a base black master batch at a higher loadingthan the upper limit of 3 wt. % that has traditionally been employed forsmall-particle (200 mesh), fully-vulcanized, ground tire rubber. Inother words, the interlinked substituted rubber material was observed tobe suitable for use in fabricating tires as the sole rubber source, orit can be used in combination with base black master batch at loadingsabove 3%, e.g., 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50,55, 60, 65, 70, 75, 80, 85, 90, or 95 wt. % or more.

The interlinked substituted rubber material was observed to be nearelemental sulfur-free, to have a morphology similar to composite virginrubber, to be <50 micron in particle size, with substantial elastomerretention of the carbon black. The material is suitable for use as atleast 20% and up to 50, 60%, 70, 80, 90%, or more (e.g., as much as100%) of the sidewall of new, light truck and auto tires. Such aninterlinked substituted rubber material is also suitable for use inmembranes and industrial rubber goods.

IPREX Rubber Polymer

InterPenetrating Regenerative Elastomer Xlink (IPREX) Rubber Polymer(IRP) is a microlaminated, anisotropic structural rubber sheet. It iscomposed of multiple, vacuum-heat fused and cross linked layers, eachbeing in the range of 10-70 microns thick. The material comprises carbonfilled, interpenetrating polyisoprene-polybutadiene elastomer chains,regenerative, realigned crosslinks by transverse sulfidic bridges. Theindividual laminae exhibit a near-zero loop probability andbias-directional, parallel-reptated, intertwined, elastomer backbonestructure(s) which, when progressively laid-up during construction at30-45 degrees to the anisotropic ‘grain’ of each preceding laminae,produces a finished sheet exhibiting superior torsional strength andresilience to comparable isotropic sheets of similar material andcross-section thickness. Pre-cross linked feedstock is processed intothin laminae through a variable nip, high pressure roll mill. IPREXRubber may be fabricated in two steps from previously cross linked,black master batch virgin feedstock prepared for tire or otherengineered rubber products and/or EOL whole tire scrap which hassubsequently been parted into small rubber particles (typically 30 mesh,ambient ground tire rubber), which are then subsequently re-compoundedaccording to predetermined, PRISM Reactor process parameters asdescribed herein. IPREX Rubber may be compounded to form aninterpenetrating and cross linked, elastomer network with otherelastomers, such as functionalized SiR, for enhanced chemical and heatresistance. IPREX rubber is suitable for use in tire wall construction,code compliant electrical tape and potting compounds, industrial beltingand hoses, high temperature fabrics and gaskets, geo-liners, roofing andwaterproofing membranes, colloidal suspensions for industrial adhesives,and super-pave, PG hot-melt, asphalt binder modification.

Post-Reactor GTRP-Containing Vehicle Tire Performance

The post-reactor GTRP has a clumpy, non-uniform appearance exiting thereactor. After drying and compounding with cross-link agents and otheroptional hybrid elastomers, typically accomplished in a high shear,internal mixer such as a twin arm Banbury or sigma blade mixer, the GTRPis passed through a narrow, roll mill nip where it becomes a thin sheet.This thin sheet, unlike conventional, virgin, black master batch (VBMB)elastomer composite compounds, similarly processed, may exhibit ananisotropy in length tensile strength to width tensile strength of up toapprox. 3:1. The factors that may contribute to the degree of anisotropyinclude the reactor-controlled loop probability reduction, manipulationof the degree of crosslink dislocation, and/or reduction of internalmixing time.

Reactor Controlled Loop Probability Reduction

This factor can statistically add, on average, 12.5% by weight ofadditional, effective elastomer to the resulting matrix, inasmuch asonce the same-backbone, methyl carbocation precursor-bonded, sulfuricbridge is dislocated, the elastomer is released to dynamically orient(and remain so) as a reptation-bias, along the lateral axis ofcompression-travel (which is perpendicular the face of the roll millnip).

Manipulation of the Degree of Cross Link Dislocation

The resilience of remaining, EOL tire cross-links induce a variable,residual resistance to size reduction during compounding and final sheetpreparation, wherein the not-fully dislocated particle resists beingflattened by the roll mill pressure. This appendage acts as an anchor,being drug along by that portion of the elastomer matrix that morereadily achieves reptate-like dynamics. The effect is a reptate-bias inthe lateral direction of compression-travel between the rolls.

Reduction of Internal Mixing Time

Post-reactor, GTRP particle, final particle size reduction is a functionof the number of wiping cycles the particle endures within the mixer(e.g., twin arm mixer). Since typically only minimal amounts ofadditives are employed to prepare the GTRP for milling into a sheet formany applications, excessive high shear is not necessitated except whenthe taking the clumps into progressively smaller dimensions is desired.This manipulation in mixing time can have a similar, but slightly lesspronounced, dragging-anchor-effect to that previously described herein.

Where isotropism is advantageous, the GTRP can be handled in a mannerwhich is the inverse of these three discriminators. However, unlikeVBMB, the anisotropic quality can have great advantage in structureswhich must undergo persistent flexing, yet remain dimensionally stable,such as the sidewall of a vehicle tire.

Treated Rubber for Tire Applications

Industry averages place approx. 15% of the vehicle's operational fuelconsumption upon overcoming the rolling resistance of the vehicle tire.Most of that resistance is due to tire squirm as, with each revolution,the tread wanders back and forth in an irregular, sinusoidal pattern tothe direction of travel as the tread section comes in contact with thepavement. This distortion is restrained by the resilient, torsionalproperties of the tire sidewall, transmitted to the solid rim andsuspension of the vehicle. Tire manufacturing design and constructionutilizes a reinforcement fabric, placed at 15-90 degrees to thevertical, rolling tire plane, which is laminated between the isotropicVBMB to achieve a composite structure that maintains a safe, effectiverolling structure. However, it takes significant energy to overcome thebroad range of torsional mechanics associated with traveling over avariety of surface conditions at variable speeds.

A 40 mil (˜1 mm) thick micro-laminated, GTRP sheet, composed of four0.010″ thick sheets laid-up as a four, micro-ply assembly, with eachsub-ply placed at approximately 45 degrees to the succeeding laminate,demonstrates an increase of approximately 30% or more in resistance totorsional distortion as compared to a similarly prepared VBMBmicro-laminate. Using quantified foot-pound force, torsional mechanicalmodels, a tire construction utilizing this anisotropic micro-laminate,particularly as a component in the two outer-most laminates of tireconstruction, where the stress from dimensional radius of distortion isthe greatest, predicts rolling resistance reduction per unit of tirecarcass weight of between 9.5% and 16%. A ten percent (10%) reduction intire rolling resistance, based upon current global fuel consumption,equates to an annual savings of over six billion gallons (6,000,000,000gal) of fuel. Accordingly, the treated rubber of the embodiments isparticularly useful in tire applications, e.g., as microlaminated sheets(e.g., 2-100 or more sheets, e.g., 2-20, 2-20, or 2-5 sheets laminatedtogether) for use in tire sidewall applications.

Treated Rubber for High Performance Applications

The rubbers and rubber-containing materials of the various embodimentsmay be manufactured to meet one or more of the following specifications.In certain embodiments, rubber and rubber goods meeting one or more ofthe MIL-R specifications listed below are provided. These can includebut are not limited to tire tread, tire sidewall, roofing membrane, highdielectric electrical tape, tank lining, reservoir lining, trenchlining, bridge underlayment, foundation waterproofing, parking garagewaterproofing, hose, belt, molding, or other rubber goods prepared frommolded rubber or rubber sheeting (e.g., gaskets, tubing, shock absorbingmaterials, floor mats and bed liners for vehicles, mats and flooringmaterials for commercial and residential construction, underlayments forfloors, decking, and concrete, sound proofing, etc.) Other productsinclude elasticized bands in clothing and hair ties, dishwashing gloves,toys, jar seals and tires, welcome mats, garden hoses. Other householdrubber items include boots, raincoats, pond liners, mattresses andcushions, pillows, grips on garden tools, bathtub plugs, doorstops,earplugs, hot water bottles, aquarium tubing, faucet washers and backingfor rugs. Stoppers for lab flasks and vials, chemical resistant mats andpads, prosthetics and other specialized products and equipment can bemade from the rubber of the embodiments, as can rubber food and waterbowls, chew toys and balls, foam rubber mattress pads, stall mats,elasticized vet wraps, flea collars, shed mitts and rubber combs, mousepads, keyboards, adhesives and rolling chair wheels, anti-fatigue mats,carpet underlayment, head phone pads and rubber stamps, inflatable bedsfor camping, playground tiles, rubber ducks, sportswear, scuba suits,vehicle components for civilian and military use; boat, ship, andsubmarine components for civilian or military use; airplane, passengerplane, and fighter jet components, railcar and train engine components,residential and commercial building products, factory or industrial ormanufacturing components, clothing and footwear components.

The treated rubber of the embodiments may be employed in rubber productsthat meet or exceed one or more of the following ASTM specifications,military specifications (MIL), aerospace material specifications (AMS),and/or other specifications as are employed in various industries usingrubber goods.

ASTM C542 (ASTM C 1166 Procedure)—Low Smoke, Low Flame, Low ToxicityNeoprene

ASTM E662—Low Smoke, Low Flame, Low Toxicity Neoprene

ASTM D1330 Grade 1—Premium SBR—Style 22

ASTM D1330 Grade 2—Red Rubber SBR—Style 20

ASTM D2000 1AA 430—Natural Rubber—Style 28

ASTM D2000 1AA 704 Z1 (Z1=75±5 Durometer)—Red Rubber SBR—Style 20

ASTM D2000 M1AA 407—Butyl

ASTM D2000 M1AA 417—Natural Rubber, Pure Gum Floating Natural Rubber, EZCut Non-Floating Gum Natural Rubber, Protein Free (SyntheticPolyisoprene) Natural Rubber

ASTM D2000 M1AA 503—Commercial EPDM

ASTM D2000 M1AA 507—Butyl

ASTM D2000 M1AA 517—Natural Rubber

ASTM D2000 M1AA 606—Commercial EPDM

ASTM D2000 M1AA 607—Butyl

ASTM D2000 M1AA 617—Natural Rubber

ASTM D2000 M1AA 703 Z1 (Z1=75±5 Durometer)—Specification Grade SBR (Red)

ASTM D2000 M1AA 706—Commercial EPDM

ASTM D2000 M1AA 710—Butyl

ASTM D2000 M4AA 407 A13 B13 C12 F17

ASTM D2000 M4AA 421 F17 G21—Tuff-Stuff® Natural Rubber

ASTM D2000 M4AA 510 A13 B13 C12 F17—ASTM D2000 M4AA Specification Grade(EPDM)

ASTM D2000 M4AA 610 A13 B13 C12 F17

ASTM D2000 M4AA Specification Grade (EPDM)

ASTM D2000 M4AA 710 A13 B13 C12 F17

ASTM D2000 M4AA Specification Grade (EPDM)

ASTM D2000 M2BA 407 C12 F17—Premium EPDM—Style 45

ASTM D2000 3BA 508 C12—Commercial EPDM—Style 40

ASTM D2000 3BA 515 A14 B13 C12 F17—Premium EPDM—Style 45

ASTM D2000 3BA 608 C12—Commercial EPDM—Style 40

ASTM D2000 3BA 615 A14 B13 C12 F17—Premium EPDM—Style 45

ASTM D2000 3BA 708 C12—Commercial EPDM—Style 40

ASTM D2000 3BA 715 A14 B13 C12 F17—Premium EPDM—Style 45

ASTM D2000 3BA 815 A14 B13 C12 F17—Premium EPDM—Style 45

ASTM D2000 1BC 408—Commercial Neoprene—Style 10

ASTM D2000 1BC 508—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

ASTM D2000 1BC 515—Mid-Grade Neoprene—Style 15

ASTM D2000 1BC 609—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

ASTM D2000 1BC 615—Mid-Grade Neoprene—Style 15

ASTM D2000 1BC 710—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

ASTM D2000 1BC 715—Mid-Grade Neoprene—Style 15

ASTM D2000 1BC 810—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

ASTM D2000 M1BC 303—Mid-Grade Neoprene—5100 Series, Premium Neoprene

ASTM D2000 M1BC 403—Mid-Grade Neoprene—5100 Series, Neoprene MoldedSlabs

ASTM D2000 M1BC 407—Premium Neoprene ASTM D2000 M1BC 507—Mid-GradeNeoprene—5100 Series, Neoprene Molded Slabs

ASTM D2000 M1BC 510—Premium Neoprene ASTM D2000 M1BC 607—Mid-GradeNeoprene—5100 Series, Neoprene Molded Slabs

ASTM D2000 M1BC 610—Premium Neoprene

ASTM D2000 M1BC 707—Mid-Grade Neoprene—5100 Series, Neoprene MoldedSlabs

ASTM D2000 M1BC 710—Premium Neoprene

ASTM D2000 M1BC 807—Mid-Grade Neoprene—5100 Series, Neoprene MoldedSlabs

ASTM D2000 M1BC 810—Premium Neoprene

ASTM D2000 M1BC 907—Premium Neoprene

ASTM D2000 M2BC 407 A14 B14 C12 F17 Z1—(Z1=Fungus Resistance per MIL STD810, Method 508), Anti-Microbial Neoprene

ASTM D2000 M2BC 410 A14 B14 C12 EO34 F17

ASTM D2000 M2BC Specification Grade (Neoprene)

ASTM D2000 M2BC 510 A14 B14 C12 F17 Z1—(Z1=Fungus Resistance per MIL STD810, Method 508), Anti-Microbial Neoprene

ASTM D2000 M2BC 510 A14 B14 C12 EO34 F17

ASTM D2000 M2BC Specification Grade (Neoprene)

ASTM D2000 M2BC 610 A14 B14 C12 F17 Z1—(Z1=Fungus Resistance per MIL STD810, Method 508), Anti-Microbial Neoprene

ASTM D2000 M2BC 610 A14 B14 C12 EO34 F17

ASTM D2000 M2BC Specification Grade (Neoprene)

ASTM D2000 M2BC 710 A14 B14 C12 EO34 F17

ASTM D2000 M2BC Specification Grade (Neoprene)

ASTM D2000 MICA 410—Peroxide Cure EPDM

ASTM D2000 MICA 510—Peroxide Cure EPDM

ASTM D2000 MICA 610—Peroxide Cure EPDM

ASTM D2000 MICA 710—Peroxide Cure EPDM

ASTM D2000 MICA 810—Peroxide Cure EPDM

ASTM D2000 1BF 408 Z1 (Z1=Meets basic requirements of BF materials),Commercial Nitrile (Buna-N)—Style 35

ASTM D2000 1BF 508 Z1 (Z1=Meets basic requirements of BF materials),Commercial Nitrile (Buna-N)—Style 35

ASTM D2000 1BF 609—Commercial Nitrile (Buna-N)—Style 35

ASTM D2000 1BF 710—Commercial Nitrile (Buna-N)—Style 35

ASTM D2000 1BF 810—Commercial Nitrile (Buna-N)—Style 35

ASTM D2000 1BG 610—FDA Nitrile (Buna-N)—Style 37

ASTM D2000 M1BG 407—Premium Nitrile (Buna-N)

ASTM D2000 M1BG 503 Z1 (Z1=45±5 Durometer), WARCO White® FDA Nitrile(Buna-N)

ASTM D2000 M1BG 507—Premium Nitrile (Buna-N)

ASTM D2000 M1BG 607 Z1 (Z1=55±5 Durometer), WARCO White® FDA Nitrile(Buna-N)

ASTM D2000 M1BG 610—Premium Nitrile (Buna-N)

ASTM D2000 M1BG 707 Z1 (Z1=65±5 Durometer), WARCO White® FDA Nitrile(Buna-N)

ASTM D2000 M1BG 710—Premium Nitrile (Buna-N)

ASTM D2000 M1BG 803—WARCO White® FDA Nitrile (Buna-N)

ASTM D2000 M1BG 810—Premium Nitrile (Buna-N)

ASTM D2000 M1BG 910—Premium Nitrile (Buna-N)

ASTM D2000 5BG 613 A14 B14 EO14 EO14 F17—Premium Nitrile (Buna-N)—Style36

ASTM D2000 5BG 620 A14 B14 EO34—Transformer Oil Nitrile (Buna-N)

ASTM D2000 5BG 720 A14 B14 EO34—Transformer Oil Nitrile (Buna-N)

ASTM D2000 MSBG 407 A14 B14 EO14 EO34 F17—ASTM D2000 MSBG SpecificationGrade (Nitrile/Buna-N)

ASTM D2000 MSBG 507 A14 B14 EO14 EO34 F17—ASTM D2000 MSBG SpecificationGrade (Nitrile/Buna-N)

ASTM D2000 MSBG 610 A14 B14 EO14 EO34 F17—ASTM D2000 MSBG SpecificationGrade (Nitrile/Buna-N)

ASTM D2000 MSBG 710 A14 B14 EO14 EO34 F17—ASTM D2000 MSBG SpecificationGrade (Nitrile/Buna-N)

ASTM D2000 M1HK 607—Premium Viton® A: 66% Fluorine

ASTM D2000 M1HK 707—Premium Viton® A: 66% Fluorine, Premium Viton® B:68% Fluorine

ASTM D2000 M1HK 807—Premium Viton® A: 66% Fluorine

ASTM D2000 M1HK 807 Z1 (Z1=75±5 Durometer), Premium Viton® B: 68%Fluorine

MIL-R-900—MIL-R-900 Specification Grade

MIL-G-1149—MIL-G-1149 Type 1 Class 1 Grade 50—MIL-R-1149 SpecificationGrade (Neoprene)

MIL-G-1149 Type 1 Class 2 Grade 50—MIL-R-1149 Specification Grade (SBR)

MIL-G-1149 Type 1 Class 5 Grade 50—MIL-R-1149 Specification Grade(Nitrile/Buna-N)

MIL-R-2765—MIL-R-2765 Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SB 410 F2—MIL-R-3065 SB Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SB 515 F2—MIL-R-3065 SB Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SB 615 F2—MIL-R-3065 SB Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SB 715 F2—MIL-R-3065 SB Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SB 815 F2—MIL-R-3065 SB Specification Grade (Nitrile/Buna-N)

MIL-R-3065 SC 310 F1—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 SC 408 Z1 (Z1=350% minimum Elongation), CommercialNeoprene—Style 10

MIL-R-3065 SC 410 F2—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 SC 508—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

MIL-R-3065 SC 515 F2—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 SC 609—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

MIL-R-3065 SC 615 F2—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 SC 710—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

MIL-R-3065 SC 715 F2—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 SC 810—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

MIL-R-3065 SC 815 F1—MIL-R-3065 SC Specification Grade (Neoprene)

MIL-R-3065 RS 508 C1—Commercial EPDM—Style 40

MIL-R-3065 RS 515 C1 F1—Premium EPDM—Style 45

MIL-R-3065 RS 608 C1—Commercial EPDM—Style 40

MIL-R-3065 RS 615 C1 F1—Premium EPDM—Style 45

MIL-R-3065 RS 708 C1—Commercial EPDM—Style 40

MIL-R-3065 RS 715 C1 F1—Premium EPDM—Style 45

MIL-R-3065 RS 815 C1 F1—Premium EPDM—Style 45

MIL-R-6855 Class 1 Grade 40—MIL-R-6855 Class 1 Fuel ResistantSpecification Grade (Nitrile/Buna-N)

MIL-R-6855 Class 1 Grade 50—MIL-R-6855 Class 1 Fuel ResistantSpecification Grade (Nitrile/Buna-N)

MIL-R-6855 Class 1 Grade 60—MIL-R-6855 Class 1 Fuel ResistantSpecification Grade (Nitrile/Buna-N)

MIL-R-6855 Class 1 Grade 70—MIL-R-6855 Class 1 Fuel ResistantSpecification Grade (Nitrile/Buna-N)

MIL-R-6855 Class 1 Grade 80—MIL-R-6855 Class 1 Fuel ResistantSpecification Grade (Nitrile/Buna-N)

MIL-R-6855 Class 2, Grade 30—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-6855 Class 2, Grade 40—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-6855 Class 2, Grade 50—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-6855 Class 2, Grade 60—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-6855 Class 2, Grade 70—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-6855 Class 2, Grade 80—MIL-R-6855 Class 2 Oil ResistantSpecification Grade (Neoprene)

MIL-R-21252—MIL-R-21252 Specification Grade (EPDM)

MIL-R-83248C Type 2 Class 1—Fluorozone® Mil-Spec Performance FKM,Military Specification Grade Viton® A, MIL-R-83285

MIL-R-83285 Grade 80—MIL-R-83285 Grade 80 Specification Grade (EPDM)

AMS 3205—Aerospace Material Specification (AMS) Grade Low Temperature(Neoprene)

AMS 3208—Aerospace Material Specification (AMS) Grade Weather Resistant(Neoprene)

AMS 3215—Aerospace Material Specification (AMS) Grade Fuel Resistant(Nitrile/Buna-N)

AMS 3216—Fluorozone® Mil-Spec Performance FKM, Military SpecificationGrade Viton® A

AMS 3301—INFINISIL™ Spec-Grade Performance Silicone

AMS 3302—INFINISIL™ Spec-Grade Performance Silicone

AMS 3303—INFINISIL™ Spec-Grade Performance Silicone

AMS 3304—INFINISIL™ Spec-Grade Performance Silicone

FDA Approved Ingredients per 21 CFR 177.2600—FDA Neoprene, WARCO White®FDA Nitrile, Natural Rubber—Style 28, Pure Gum Floating Natural Rubber,Fluorozone® FDA Performance FKM, FDA Viton® A: 66% Fluorine, FDA RedSilicone, FDA White Silicone, FDA Approved Grade TPE (Black), FDAApproved Grade TPE (Neutral)

NSF 51—NSF 51 & NSF 61 Approved Grade TPE

NSF 61—NSF 51 & NSF 61 Approved Grade TPE

A-A-59588 2A & 2B—INFINISIL™ Spec-Grade Performance Silicone

SAE J200 1AA 430—Natural Rubber—Style 28

SAE J200 3BA 508 C12—Commercial EPDM—Style 40

SAE J200 3BA 515 A14 B13 C12 F17—Premium EPDM—Style 45

SAE J200 3BA 608 C12—Commercial EPDM—Style 40

SAE J200 3BA 615 A14 B13 C12 F17—Premium EPDM—Style 45

SAE J200 3BA 708 C12—Commercial EPDM—Style 40

SAE J200 3BA 715 A14 B13 C12 F17—Premium EPDM—Style 45

SAE J200 3BA 815 A14 B13 C12 F17—Premium EPDM—Style 45

SAE J200 1BC 408—Commercial Neoprene—Style 10

SAE J200 1BC 508—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

SAE J200 1BC 609—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

SAE J200 1BC 710—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

SAE J200 1BC 810—Commercial Neoprene—Style 10, Matte FinishNeoprene—Style 12

SAE J200 1BF 608 Z1 (Z1=40±5 Durometer)—Commercial Nitrile(Buna-N)—Style 35

SAE J200 1BF 608 Z1 (Z1=50±5 Durometer)—Commercial Nitrile(Buna-N)—Style 35

SAE J200 1BF 609—Commercial Nitrile (Buna-N)—Style 35

SAE J200 1BF 710—Commercial Nitrile (Buna-N)—Style 35

SAE J200 1BF 810—Commercial Nitrile (Buna-N)—Style 35

AASHTO Grade 2—AASHTO Unsupported Neoprene Bearing Pads—Style 71, AASHTOUnsupported Calendered Neoprene Bearing Pads, AASHTO Unsupported MoldedNeoprene Bearing Pads, AASHTO Unsupported Neoprene Bearing Pads—Style 72

AASHTO Grade 3—AASHTO Unsupported Calendered Neoprene Bearing Pads,AASHTO Unsupported Molded Neoprene Bearing Pads

Caltrans 51-1.14 Waterstops—Cal-Trans Strip Water Stops

Boeing BSS 7239—Low Smoke, Low Flame, Low Toxicity Neoprene

Bombardier SMP 800—C—Low Smoke, Low Flame, Low Toxicity Neoprene

GMP.E/P.002—General Purpose Grade TPE (Neutral)

GMP.E/P.003—General Purpose Grade TPE (Neutral)

GMP.E/P.004—General Purpose Grade TPE (Neutral)

GMP.E/P.005—General Purpose Grade TPE (Neutral)

GMP.E/P.006—General Purpose Grade TPE (Neutral)

GMP.E/P.007—General Purpose Grade TPE (Neutral)

MSAR20A—General Purpose Grade TPE (Black)

MSAR2OB—General Purpose Grade TPE (Neutral)

MSAR20C—General Purpose Grade TPE (Neutral)

MSAR2OD—General Purpose Grade TPE (Neutral)

MSAR2OE—General Purpose Grade TPE (Neutral)

MSAR30A—General Purpose Grade TPE (Neutral)

MSAR3OB—General Purpose Grade TPE (Neutral)

MSAR40A—Flame Retardant Grade TPE

MSAR40B—Flame Retardant Grade TPE

WSD-M2D379-A1—General Purpose Grade TPE (Neutral)

WSD-M2D380-A1—General Purpose Grade TPE (Neutral)

WSD-M2D381-A1—General Purpose Grade TPE (Neutral)

WSD-M2D382-A1—General Purpose Grade TPE (Neutral)

WSD-M2D441-A—General Purpose Grade TPE (Neutral)

WSD-M2D712-A1—General Purpose Grade TPE (Neutral)

HHP-151F—HHP-151F Cloth-Inserted (CI), Fungus Resistant, Anti-MicrobialNeoprene

General Electric EA12C11E7—Transformer Oil Nitrile (Buna-N)

ASTM D 178-93 Type 1 Class 2—ASTM Switchboard Type 1 Rubber Matting

ASTM D2000 1AA—Corrugated Matting, Heavy Corrugated Matting, LightweightKleenRite® Matting, Molded Slabs

AASHTO Grade 2—AASHTO Unsupported Molded Neoprene Bearing Pads

AASHTO Grade 3—AASHTO Unsupported Molded Neoprene Bearing Pads PRISM™Rubber Polymer

The treated rubber of certain embodiments may be employed in PRISM™Rubber Polymer, a polybutadiene-butyl rubber hybrid master batchmaterial incorporating Phase Reticulation Induced Sulfidic Metathesis(PRISM). PRISM™ Rubber Polymer may be compounded to have as many aseight additional polymers mixed in, but more typically not more thanthree additional polymers (e.g., SBR, natural rubber, and/or EPDM),depending upon the end use. PRISM™ Rubber Polymer incorporates aninterpenetrating, dual elastomer network where two distinctly differentbackbone chemistries have been woven together and then cross linkedseparate from one another. This process achieves superior triaxial andtorsional mechanical properties when compared to conventional masterbatch material for superior stability in all applications. Advantagesfor PRISM™ Rubber Polymer include a high performance to cost ratio,improved mechanical, chemical and electrical properties, excellentoxidation resistance, significant reduction of carbon footprint,sustainable polymer chemistry. PRISM™ Rubber Polymer is suitable for usein tire sidewall, roofing membranes, high dielectric electrical tape,tank lining, reservoir lining, trench lining, bridge underlayment,foundation waterproofing, parking garage waterproofing, rubber hoses,rubber belts, and rubber molding.

Exemplary Methods, Apparatus and Compositions

Method 1: A method for preparing a modified rubber, comprising:introducing an aqueous slurry comprising vulcanized rubber particles andan organometallic compound into an electromechanical reactor configuredto generate a phase space environment with cavitation, so as to inducedelamination of a rubber matrix within the vulcanized rubber particlesas coordinated with disrupting sulfidic linkages.

Method 2: The method of Method 1, further comprising reestablishingdislocated sulfidic linkages to establish within the matrix sulfurbridge cross linked, re-aligned, laminates.

Method 3: The method of Method 1, wherein delamination is associatedwith a portion of rigid sulfidic bridges of the vulcanized rubberparticles becoming unbound at an original methyl carbocation whileremaining tethered at an original allylic carbocation.

Method 4: The method of Method 1, wherein the organometallic compoundcomprises a metal having octahedral molecular geometry.

Method 5: The method of Method 1, wherein the organometallic compoundcomprises a metal ion selected from the group consisting of Co²⁺, Cu²⁺,Ni²⁺, Zn²⁺, and Mn²⁺.

Method 6: The method of Method 1, wherein the organometallic compoundcomprises an organic anion as a ligand to the metal ion.

Method 7: The method of Method 6, wherein the organic anion comprisesacetate ion.

Method 8: The method of Method 1, wherein the organometallic compound iscopper acetate.

Method 9: The method of Method 1, wherein the organometallic compound isa metal salt that undergoes a phase change from solid to liquid in arange of 115-150° C.

Method 10: The method of Method 1, wherein a temperature in theelectromechanical reactor is maintained at ambient by use of a coolingjacket or cooling coils.

Method 11: The method of Method 1, wherein the vulcanized rubber crumbshave a particle size greater than 200 mesh.

Reactor 12: An electromechanical reactor comprising: a rotor having aplurality of slots; and a stator, wherein the electromechanical reactoris configured to create a phase space environment by generating amixture of entrained air, an organometallic compound, and ground tirerubber particles in a liquid subject to cavitation.

Matrix 13: A rubber-based heterogeneous matrix comprising aninterpenetrating network of two or more elastomers, the networkcomprising sulfur bridge cross linked, re-aligned, intermingledlaminates having an average spacing of from 10 nm to 5 microns, whereineach laminate comprises one of the two or more elastomers.

Matrix 14: The matrix of Matrix 13, further comprising carbon blackparticles dispersed amongst the laminates.

Matrix 15: The matrix of Matrix 13, wherein the two or more elastomerscomprise virgin natural rubber and an elastomer derived from ground tirerubber.

Matrix 16: The matrix of Matrix 13, wherein the two or more elastomerscomprise virgin styrene butadiene/butadiene rubber and an elastomerderived from ground tire rubber.

Matrix 17: The matrix of Matrix 13, wherein two of the two or moreelastomers have different backbone chemistries.

Matrix 18: The matrix of Matrix 13, wherein the two of the two or moreelastomers having the different backbone chemistries are woven togetherand then cross linked separate from one another.

Sheet 19: A sheet of the rubber-based heterogeneous matrix of Matrix 13.

Sheet 20: The sheet of Sheet 19, exhibiting an anisotropy in lengthtensile strength to width tensile strength, wherein the anisotropy inlength tensile strength to width tensile strength is from 1.1:1 to 3:1.

Laminate 21: A laminate comprising a plurality of the sheets of Sheet19.

Laminate 22: The laminate of Laminate 21, wherein each of the sheets hasa thickness in a range of 10 to 70 microns.

Laminate 23: The laminate of Laminate 21, wherein each of the sheets isvacuum-heat fused and cross linked to an adjacent sheet.

Laminate 24: The laminate of Laminate 21, wherein each of the sheets isoriented 30 to 45 degrees to an anisotropic grain of an adjacent sheet.

Structure 25: A ground tire rubber composite structure having anunbound, reptated internal morphology, wherein a portion of the rigidsulfidic linkages therein are each tethered at an original allyliccarbocation and unbound at an original methyl carbocation.

Vulcanized Rubber 26: A vulcanized rubber, wherein a portion of therigid sulfidic linkages therein are each tethered at an original allyliccarbocation and unbound at an original methyl carbocation, and wherein aportion of polymer backbones within the vulcanized rubber aresubstituted by an acetate moiety.

Interlinked Substituted Rubber 27: An interlinked substituted rubbersubstantially as described herein.

Article 28: A tire tread, tire sidewall, roofing membrane, highdielectric electrical tape, tank lining, reservoir lining, trenchlining, bridge underlayment, wire harness wrap, self-bonding wireharness wrap, shoe soles, rubber boots, electrical tape, foundationwaterproofing, parking garage waterproofing, hose, belt, or moldingcomprising an interlinked substituted rubber product as describedherein.

Rubber Tire 29: A rubber tire, wherein from 3% by weight to 15% byweight of the rubber in the tire is prepared by a method substantiallyas described herein.

Rubber Tire 30: A rubber tire, wherein from 15% by weight to 100% byweight of the rubber in the tire is prepared by a method substantiallyas described herein.

Tire Tread 31: A tire tread comprising from 10% by weight to 50% byweight of an interlinked substituted rubber substantially as describedherein.

Tire Sidewall 32: A tire sidewall comprising from 5% by weight to 100%by weight of an interlinked substituted rubber substantially asdescribed herein.

Asphalt-Rubber Binder 33: An asphalt-rubber binder comprising from 5% byweight to 95% by weight of an interlinked substituted rubbersubstantially as described herein.

Asphalt Emulsion 34: An asphalt emulsion comprising from 5% by weight to95% by weight of an interlinked substituted rubber substantially asdescribed herein.

Asphalt Roofing Material 35: An asphalt roofing material comprising from5% by weight to 95% by weight of an interlinked substituted rubbersubstantially as described herein.

While the disclosure has been illustrated and described in detail in thedrawings and foregoing description, such illustration and descriptionare to be considered illustrative or exemplary and not restrictive. Thedisclosure is not limited to the disclosed embodiments. Variations tothe disclosed embodiments can be understood and effected by thoseskilled in the art in practicing the claimed disclosure, from a study ofthe drawings, the disclosure and the appended claims.

All references cited herein are incorporated herein by reference intheir entirety. To the extent publications and patents or patentapplications incorporated by reference contradict the disclosurecontained in the specification, the specification is intended tosupersede and/or take precedence over any such contradictory material.

Unless otherwise defined, all terms (including technical and scientificterms) are to be given their ordinary and customary meaning to a personof ordinary skill in the art, and are not to be limited to a special orcustomized meaning unless expressly so defined herein. It should benoted that the use of particular terminology when describing certainfeatures or aspects of the disclosure should not be taken to imply thatthe terminology is being re-defined herein to be restricted to includeany specific characteristics of the features or aspects of thedisclosure with which that terminology is associated. Terms and phrasesused in this application, and variations thereof, especially in theappended claims, unless otherwise expressly stated, should be construedas open ended as opposed to limiting. As examples of the foregoing, theterm ‘including’ should be read to mean ‘including, without limitation,’‘including but not limited to,’ or the like; the term ‘comprising’ asused herein is synonymous with ‘including,’ containing,′ or‘characterized by,’ and is inclusive or open-ended and does not excludeadditional, unrecited elements or method steps; the term ‘having’ shouldbe interpreted as ‘having at least;’ the term ‘includes’ should beinterpreted as ‘includes but is not limited to;’ the term ‘example’ isused to provide exemplary instances of the item in discussion, not anexhaustive or limiting list thereof; adjectives such as ‘known’,‘normal’, ‘standard’, and terms of similar meaning should not beconstrued as limiting the item described to a given time period or to anitem available as of a given time, but instead should be read toencompass known, normal, or standard technologies that may be availableor known now or at any time in the future; and use of terms like‘preferably,’ preferred,′ ‘desired,’ or ‘desirable,’ and words ofsimilar meaning should not be understood as implying that certainfeatures are critical, essential, or even important to the structure orfunction of the invention, but instead as merely intended to highlightalternative or additional features that may or may not be utilized in aparticular embodiment of the invention. Likewise, a group of itemslinked with the conjunction ‘and’ should not be read as requiring thateach and every one of those items be present in the grouping, but rathershould be read as ‘and/or’ unless expressly stated otherwise. Similarly,a group of items linked with the conjunction ‘or’ should not be read asrequiring mutual exclusivity among that group, but rather should be readas ‘and/or’ unless expressly stated otherwise.

Where a range of values is provided, it is understood that the upper andlower limit, and each intervening value between the upper and lowerlimit of the range is encompassed within the embodiments.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for sakeof clarity. The indefinite article “a” or “an” does not exclude aplurality. A single processor or other unit may fulfill the functions ofseveral items recited in the claims. The mere fact that certain measuresare recited in mutually different dependent claims does not indicatethat a combination of these measures cannot be used to advantage. Anyreference signs in the claims should not be construed as limiting thescope.

It will be further understood by those within the art that if a specificnumber of an introduced claim recitation is intended, such an intentwill be explicitly recited in the claim, and in the absence of suchrecitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to embodiments containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, and C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). In those instances where aconvention analogous to “at least one of A, B, or C, etc.” is used, ingeneral such a construction is intended in the sense one having skill inthe art would understand the convention (e.g., “a system having at leastone of A, B, or C” would include but not be limited to systems that haveA alone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that virtually any disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms. For example, the phrase “A or B” will be understood toinclude the possibilities of “A” or “B” or “A and B.”

All numbers expressing quantities of ingredients, reaction conditions,and so forth used in the specification are to be understood as beingmodified in all instances by the term ‘about.’ Accordingly, unlessindicated to the contrary, the numerical parameters set forth herein areapproximations that may vary depending upon the desired propertiessought to be obtained. At the very least, and not as an attempt to limitthe application of the doctrine of equivalents to the scope of anyclaims in any application claiming priority to the present application,each numerical parameter should be construed in light of the number ofsignificant digits and ordinary rounding approaches.

Furthermore, although the foregoing has been described in some detail byway of illustrations and examples for purposes of clarity andunderstanding, it is apparent to those skilled in the art that certainchanges and modifications may be practiced. Therefore, the descriptionand examples should not be construed as limiting the scope of theinvention to the specific embodiments and examples described herein, butrather to also cover all modification and alternatives coming with thetrue scope and spirit of the invention.

What is claimed is:
 1. A rubber-based heterogeneous matrix comprising an interpenetrating network of two or more elastomers, the network comprising sulfur bridge cross linked, re-aligned, intermingled laminates having an average spacing of from 10 nm to 5 microns, wherein each laminate comprises one of the two or more elastomers.
 2. The matrix of claim 1, further comprising carbon black particles dispersed amongst the laminates.
 3. The matrix of claim 1, wherein the two or more elastomers comprise virgin natural rubber and an elastomer derived from ground tire rubber.
 4. The matrix of claim 1, wherein the two or more elastomers comprise virgin styrene butadiene/butadiene rubber and an elastomer derived from ground tire rubber.
 5. The matrix of claim 1, wherein two of the two or more elastomers have different backbone chemistries.
 6. The matrix of claim 1, wherein the two of the two or more elastomers having the different backbone chemistries are woven together and then cross linked separate from one another.
 7. The matrix of claim 1, in a form of a sheet.
 8. The matrix of claim 7, wherein the sheet exhibits an anisotropy in length tensile strength to width tensile strength, wherein the anisotropy in length tensile strength to width tensile strength is from 1.1:1 to 3:1.
 9. A laminate comprising a plurality of sheets, wherein each of the sheets comprises a rubber-based heterogeneous matrix comprising an interpenetrating network of two or more elastomers, the network comprising sulfur bridge cross linked, re-aligned, intermingled laminates having an average spacing of from 10 nm to 5 microns, wherein each laminate comprises one of the two or more elastomers.
 10. The laminate of claim 9, wherein each of the sheets exhibits an anisotropy in length tensile strength to width tensile strength, wherein the anisotropy in length tensile strength to width tensile strength is from 1.1:1 to 3:1.
 11. The laminate of claim 9, wherein each of the sheets has a thickness of from 10 microns to 70 microns.
 12. The laminate of claim 9, wherein each of the sheets is vacuum heat fused and cross linked to an adjacent sheet.
 13. The laminate of claim 9, wherein each of the sheets is oriented 30 to 45 degrees to an anisotropic grain of an adjacent sheet.
 14. An article selected from the group consisting of a rubber tire, an asphalt-rubber binder, an asphalt roofing material, an asphalt emulsion, a tire tread, a tire sidewall, a roofing membrane, a high dielectric electrical tape, a tank lining, a reservoir lining, a trench lining, a bridge underlayment, a wire harness wrap, a self-bonding wire harness wrap, a shoe sole, a rubber boot, an electrical tape, a foundation waterproofing, a parking garage waterproofing, a hose, a belt, and a molding, the article comprising a rubber-based heterogeneous matrix comprising an interpenetrating network of two or more elastomers, the network comprising sulfur bridge cross linked, re-aligned, intermingled laminates having an average spacing of from 10 nm to 5 microns, wherein each laminate comprises one of the two or more elastomers.
 15. The article of claim 14, which is a rubber tire, wherein from 3% by weight to 15% by weight of rubber in the tire is the rubber-based heterogeneous matrix.
 16. The article of claim 14, which is a rubber tire, wherein from 15% by weight to 100% by weight of the rubber in the tire is the rubber-based heterogeneous matrix.
 17. The article of claim 14, which is a tire tread comprising from 10% by weight to 50% by weight of the rubber-based heterogeneous matrix.
 18. The article of claim 14, which is a tire sidewall comprising from 5% by weight to 100% by weight of the rubber-based heterogeneous matrix.
 19. The article of claim 14, which is an asphalt-rubber binder comprising from 5% by weight to 95% by weight of the rubber-based heterogeneous matrix.
 20. The article of claim 14, which is an asphalt roofing material comprising from 5% by weight to 95% by weight of the rubber-based heterogeneous matrix. 